Abstract: A driveshaft assembly for a vehicle includes a tube having a first end and a second end. The driveshaft assembly also includes a first member configured to transmit torque. A portion of the first member is provided within the first end of the tube and is coupled to an inner surface of the tube by a weld. The driveshaft assembly also includes a second member configured to transmit torque. A portion of the second member is provided within the second end tube and is coupled to the inner surface of the tube by a weld. The first and second members are configured to have axes of rotation that are collinear with an axis of rotation of the tube such that when the first and second members are coupled to the tube, no further alignment between the tube, the first member, and the second member is required.

Abstract: A direct torque flow constant velocity joint connector includes an outer joint part, and inner joint part, a cage and a plurality of balls. The outer joint part includes outer ball tracks. The inner joint part includes inner ball tracks and a rotational axis, wherein the inner joint part has a face spline oriented about the rotational axis. The plurality of balls are provided in the cage and engage the inner and outer ball tracks of the respective inner and outer joint parts, thereby allowing torque transmission by way of the face splines. Also provided is a direct torque flow constant velocity joint connection.

Abstract: A propshaft assembly has an inner tube, an outer tube having an end splined to the inner tube thereby defining an engagement area between the inner tube and the outer tube. The propshaft assembly also includes at least one stiffening ring disposed around the outer tube. At least a portion of the stiffening ring is in contact with the outer tube.

Abstract: A sleeve assembly includes a sleeve having an inner surface with a first splined portion, and a biasing system biasing a rolling member through the first splined portion. A drive assembly includes the sleeve assembly and a shaft with a second splined portion engageable with the first splined portion of the shaft. When the sleeve assembly is coupled with the shaft to form the drive assembly, the biasing system biases the rolling member into engagement with the second splined portion of the shaft.

Abstract: A shield for sealing a joint includes a first end, a second end and an annular shell. The first end is adapted for axial retention on an outer joint part, where the outer joint part is rotationally coupled to an inner joint part. The second end is adapted for abutting contact with a semi-spherical portion of the inner joint part. The annular shell extends between the first end and the second end thereby providing a seal for the joint. Also provided is a grease shield sealing system for a direct torque flow constant velocity joint.

Abstract: A direct torque flow constant velocity joint connection interface includes a drive unit, a direct torque flow constant velocity joint connector and a sealant. The drive unit includes a shaft having a second interface surface. The direct torque flow constant velocity joint connector includes a unitary inner joint part having a first interface surface, where the first interface surface is connected to the second interface surface of the drive unit. The sealant provides filling between the first and second interface surfaces. Also provided is a direct torque flow constant velocity joint connector having sealant on an interface portion of an inner joint part and a method thereof.

Abstract: A constant velocity joint and a boot for a constant velocity joint are disclosed. The boot generally includes a first channel and a second channel. The first channel is in fluid communication with a joint chamber of the constant velocity joint. The first channel is also in communication with the second channel and generally allows airflow therethrough while resisting clogs from lubricant. Additionally, the second channel generally allows airflow therethrough to the atmosphere while resisting passage of foreign contaminants therethrough.

Abstract: An illustrative embodiment includes a propshaft system including a first constant velocity joint generally defining a first axis and having an inner first race, an outer first race, and a first grease cover mated to the outer first race. The propshaft system also includes a first flange having a first flange mating surface and a first flange contour surface. The propshaft system also includes a second constant velocity joint generally defining a second axis and having an inner second race, an outer second race, and a second grease cover mated to the outer second race. The second grease cover is defined, at least in part, by a second grease cover flange surface and a second grease cover contour surface. The propshaft system additionally includes a propshaft portion extending at least partially between the first connection apparatus and the second connection apparatus.

Abstract: A shaft assembly comprises a tubular shaft and a joint, wherein at least a portion of the joint is disposed within the tubular shaft. The present invention may also include a shaft assembly comprising a shaft and a constant velocity joint wherein the constant velocity joint is integrated into the shaft by inserting at least a portion of the constant velocity joint into the shaft. In one method of the invention, the method comprises the steps of integrating a constant velocity joint into a propeller shaft by inserting at least a portion of the constant velocity joint into the propeller shaft.

Abstract: A connecting assembly between a shaft journal and a constant velocity universal joint having an outer joint part and an inner joint part engaged by the shaft journal. The inner joint part includes an elongated neck portion with at least one insertion groove formed therein, and the shaft journal has at least one corresponding insertion groove. A securing clip engages the corresponding insertion grooves to axially secure the inner joint part and shaft journal with respect to each other. A boot is axially secured to the inner joint part neck portion, substantially enveloping the inner joint part, and sealingly engaging an outer surface of the outer joint part to seal at least one side of a joint chamber of the constant velocity universal joint.

Abstract: A direct torque flow constant velocity joint connector includes an outer joint part having outer ball tracks and an outer surface, an inner joint part with inner ball tracks, a cage, a plurality of balls held in the cage and engaging the inner and outer ball tracks, and a boot. The boot includes a first end and a second end, wherein the first end is axially secured to the outer surface of the outer joint part while providing rotational freedom between the boot and the outer joint part, and the second end is selectively attachable to a supplied drive unit.

Abstract: 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.

Abstract: A torque transfer device, such as a transfer case for a motor vehicle, having a constant velocity joint integrated therewith is disclosed. In one embodiment, the constant velocity joint includes an outer race rotatably mounted within the torque transfer device and an inner race positioned within the outer race and operatively connected to the outer race by one or more torque transmitting balls. The torque transfer device further includes a drive mechanism that is connected to the outer race of the constant velocity joint, wherein the drive mechanism transfers torque received from an input shaft to the outer race of the constant velocity joint such that the outer race drives the inner race. The torque transfer device further includes an output shaft that is rotatably connected to the inner race.

Abstract: An absorber for use within a shaft assembly of a vehicle is disclosed. The absorber includes at least one cantilever device and at least one constrained layer device. Both devices are disposed within a tube. The absorber is capable of being tuned to specific frequencies and capable of controlling the amount of damping within the shaft assembly. Also disclosed is a shaft assembly having a generally tubular shaft. Disposed within the tubular shaft is the absorber having at least one cantilever device and at least one constrained layer device.

Abstract: A direct torque flow constant velocity joint having a rolling radial boot is provided and includes a DTF CVJ connector, a shroud assembly and a rolling radial boot. The DTF CVJ connector includes an outer joint part and an inner joint part, such that the shroud assembly is connected to the inner joint part and substantially surrounds the outer joint part of the DTF CVJ. The shroud assembly includes a circumferential clamp portion so that a rolling radial boot is connected between it and the outer joint part of the DTF CVJ. The rolling radial boot is covered by the shroud assembly and seals the DTF CVJ. The shroud assembly also protects the boot from external debris.

Abstract: A shaft system for use in a vehicle is disclosed. The shaft system includes a tube. A constant velocity joint is secured to the tube. The shaft system also includes a plug arranged within the constant velocity joint wherein the plug is secured within the joint by a weld curl that is also used to secure the constant velocity joint to the tube.

Abstract: A sealing component constructed of silicone compound for use in high-temperature, high-speed and high-angle applications is disclosed. The disclosed silicone material may also be reinforced with fibers for added stiffness and stability.

Abstract: 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 (D1). In response to a sufficient inward axial load, the cylindrical body is adapted to telescope over the splined shaft through an interference region (D2) comprising an interference mechanism for energy dissipation.

Abstract: A method of forming a flexible component includes performing a stress analysis on potential configurations of the component. A desired as-molded shape can be selected from the configurations that were analyzed based upon the stresses resulting from manipulation.

Abstract: An improved boot for use in sealing a constant velocity joint and ball spline joint assembly includes a plurality of articulating convolutes, a grease catching member, and a first stabilizing member adapted to ride above an inner race of the ball spline joint to join the plurality of articulating convolutes and the grease catching member and provide stability at high speed. The boot further includes a plurality of plunging convolutes and a second stabilizing member adapted to ride above an outer race of the ball spline joint to join the plurality of plunging convolutes and the grease catching member and provide additional stability.