Abstract: A method of making a worm gear. The method includes forming a gear blank having a plurality of individual lugs formed about an outer circumferential edge of said blank to facilitate a uniform flow of a material around said plurality of individual lugs. The method also includes molding said material around said plurality of individual lugs to form a ring.

Abstract: Embodiments of a system, method and apparatus for a gear are disclosed. For example, a metallic gear hub can include an axis of rotation and metallic gear teeth. The metallic gear teeth can be smaller than a final gear teeth size of the gear. The metallic gear teeth can be co-planar with the axis. In addition, the metallic gear teeth can be non-orthogonal to the axis. A polymer layer can be located on the metallic gear teeth to form polymer gear teeth on the metallic gear teeth. The polymer gear teeth can form the final gear teeth size of the gear.

Abstract: Embodiments of a system, method and apparatus for a gear are disclosed. For example, a metallic gear hub can include an axis of rotation and metallic gear teeth. The metallic gear teeth can be smaller than a final gear teeth size of the gear. The metallic gear teeth can be co-planar with the axis. In addition, the metallic gear teeth can be non-orthogonal to the axis. A polymer layer can be located on the metallic gear teeth to form polymer gear teeth on the metallic gear teeth. The polymer gear teeth can form the final gear teeth size of the gear.

Abstract: Embodiments of a system, method and apparatus for a gear are disclosed. For example, a metallic gear hub can include an axis of rotation and metallic gear teeth. The metallic gear teeth can be smaller than a final gear teeth size of the gear. The metallic gear teeth can be co-planar with the axis. In addition, the metallic gear teeth can be non-orthogonal to the axis. A polymer layer can be located on the metallic gear teeth to form polymer gear teeth on the metallic gear teeth. The polymer gear teeth can form the final gear teeth size of the gear.

Abstract: A gear includes an inner hub formed of metal material, the inner hub having an outer surface defining a plurality of outer teeth. The gear also includes an outer ring formed of non-metal material, the outer ring having an inner diameter that is smooth. The outer ring is disposed in an interference fit with the outer teeth of the inner hub.

Abstract: A gear includes an inner hub formed of metal material, the inner hub having an outer surface defining a plurality of outer teeth. The gear also includes an outer ring formed of non-metal material, the outer ring having an inner diameter that is smooth. The outer ring is disposed in an interference fit with the outer teeth of the inner hub.

Abstract: A method of making a worm gear. The method includes forming a gear blank having a plurality of individual lugs formed about an outer circumferential edge of said blank to facilitate a uniform flow of a material around said plurality of individual lugs. The method also includes molding said material around said plurality of individual lugs to form a ring.

Abstract: Embodiments of a system, method and apparatus for a gear are disclosed. For example, a metallic gear hub can include an axis of rotation and metallic gear teeth. The metallic gear teeth can be smaller than a final gear teeth size of the gear. The metallic gear teeth can be co-planar with the axis. In addition, the metallic gear teeth can be non-orthogonal to the axis. A polymer layer can be located on the metallic gear teeth to form polymer gear teeth on the metallic gear teeth. The polymer gear teeth can form the final gear teeth size of the gear.

Abstract: Embodiments of a system, method and apparatus for a gear are disclosed. For example, a metallic gear hub can include an axis of rotation and metallic gear teeth. The metallic gear teeth can be smaller than a final gear teeth size of the gear. The metallic gear teeth can be co-planar with the axis. In addition, the metallic gear teeth can be non-orthogonal to the axis. A polymer layer can be located on the metallic gear teeth to form polymer gear teeth on the metallic gear teeth. The polymer gear teeth can form the final gear teeth size of the gear.

Abstract: A gear includes an inner hub formed of metal material, the inner hub having an outer surface defining a plurality of outer teeth. The gear also includes an outer ring formed of non-metal material, the outer ring having an inner diameter that is smooth. The outer ring is disposed in an interference fit with the outer teeth of the inner hub.

Abstract: Embodiments of a system, method and apparatus for a gear are disclosed. For example, a metallic gear hub can include an axis of rotation and metallic gear teeth. The metallic gear teeth can be smaller than a final gear teeth size of the gear. The metallic gear teeth can be co-planar with the axis. In addition, the metallic gear teeth can be non-orthogonal to the axis. A polymer layer can be located on the metallic gear teeth to form polymer gear teeth on the metallic gear teeth. The polymer gear teeth can form the final gear teeth size of the gear.

Abstract: A steering assist system of a steering column assembly is provided. The system includes a worm rotatably driven by an actuator. The system also includes a worm gear having a first set of teeth and a second set of teeth, the first set of teeth in meshed engagement with the worm, the worm gear operatively coupled to a steering shaft. The system further includes a lock feature moveable into and out of engagement with the second set of teeth of the worm gear to define a locked condition and an unlocked condition of the worm gear.

Abstract: A shaft assembly includes a yoke. The yoke defines a first bore and a second bore. The first bore extends from a first face towards a second face along a first axis. The first bore has a key that extends towards the first axis. The second bore extends from a third face towards a fourth face along a second axis that is disposed transverse to the first axis. The third face and the fourth face each extend between the first face and the second face.

Abstract: A shaft assembly includes a yoke. The yoke defines a first bore and a second bore. The first bore extends from a first face towards a second face along a first axis. The first bore has a key that extends towards the first axis. The second bore extends from a third face towards a fourth face along a second axis that is disposed transverse to the first axis. The third face and the fourth face each extend between the first face and the second face.

Abstract: A method of making a worm gear. The method includes forming a gear blank having a plurality of individual lugs formed about an outer circumferential edge of said blank to facilitate a uniform flow of a material around said plurality of individual lugs. The method also includes molding said material around said plurality of individual lugs to form a ring.

Abstract: A gear blank is provided. It includes a disk having a first face and a second face. A first plurality of individual lugs formed on said first face circumferentially adjacent an outer circumferential edge of said disk. Each lug of said first plurality of individual lugs has a first inner circumferential edge formed on said first face along a first retaining diameter. Adjacent lugs of said first plurality of individual lugs have a first circumferential spacing therebetween.

Abstract: A method of making a worm gear is provided. The method comprises forming a gear hub from a powdered metal material. Thereafter an outer surface of the gear hub is sealed.

Abstract: A vehicle steering column assembly includes a first shaft having a first shaft cavity extending from an end of the first shaft. Also included is a second shaft operatively coupled to the first shaft, the second shaft having a second shaft cavity disposed therein. Further included is a torsion bar disposed within the first shaft cavity and the second shaft cavity. Yet further included is a stop tooth extending from the first shaft. Also included is a worm gear defining a slot with a slot wall, a first portion of the slot wall configured to engage a first side of the stop tooth to define a first radial boundary of the worm gear, a second portion of the slot wall configured to engage a second side of the stop tooth to define a second radial boundary of the worm gear.

Abstract: A vehicle steering column assembly includes a first shaft having a first shaft cavity extending from an end of the first shaft. Also included is a second shaft operatively coupled to the first shaft, the second shaft having a second shaft cavity disposed therein. Further included is a torsion bar disposed within the first shaft cavity and the second shaft cavity. Yet further included is a stop tooth extending from the first shaft. Also included is a worm gear defining a slot with a slot wall, a first portion of the slot wall configured to engage a first side of the stop tooth to define a first radial boundary of the worm gear, a second portion of the slot wall configured to engage a second side of the stop tooth to define a second radial boundary of the worm gear.

Abstract: A method of making a worm gear is provided. The method comprises forming a gear hub from a powdered metal material. Thereafter an outer surface of the gear hub is sealed.