Abstract: An axle assembly having a wheel flange with a central opening and a slot having an end dimensioned to fit within the wheel flange central opening. A molten binder, such as molten zinc, fills the space in between the wheel central opening and the shaft end. Upon cooling, the binder locks the wheel flange and shaft together.

Abstract: A universal joint having a hub formed by molding a material around four stub axles which are arranged so that a first and second stub axle are axially aligned and a third and fourth stub axle are axially aligned. Furthermore, the axes of the first and second stub axles are perpendicular to and coplanar with the axes of the third and fourth stub axles. A bearing is positioned around each stub axle. A first yoke is then molded around two aligned stub axle bearings and an end of a first axle while, similarly, a second axle is molded around the bearings on the other pair of stub axles and an end of a second axle.

Abstract: A universal joint having a hub formed by molding a material around four stub axles which are arranged so that a first and second stub axle are axially aligned and a third and fourth stub axle are axially aligned. Furthermore, the axes of the first and second stub axles are perpendicular to and coplanar with the axes of the third and fourth stub axles. A bearing is positioned around each stub axle. A first yoke is then molded around two aligned stub axle bearings and an end of a first axle while, similarly, a second axle is molded around the bearings on the other pair of stub axles and an end of a second axle.

Abstract: A multi-piece crankshaft having a shaft with two ends and in which the shaft is adapted to rotate about its shaft axis and a crankpin with at least one indentation. The shaft and crankpin are placed within a mold having a first mold cavity corresponding in shape to the desired counterweight and the other end of the shaft is positioned within a second mold cavity corresponding in shape to a flywheel taper support for the crankshaft. The counterweight and flywheel taper support are then both formed by simultaneously casting a liquid material, such as zinc, into both the first and second mold cavities.

Abstract: A crankshaft assembly for an internal combustion engine having a one-piece elongated shaft adapted to rotate about a longitudinal axis. The shaft includes a radially offset portion between the ends of the shaft, and this radially offset portion is spaced axially inwardly from each end of the shaft. An elongated connecting rod having a one-piece annular bearing support at one end is secured to the shaft so that the annular bearing support is positioned around the shaft offset portion. A first counterweight is secured to the shaft adjacent one end of the shaft offset portion while a second counterweight is secured to the shaft adjacent the other end of the shaft offset portion. In an alternate embodiment, the crankshaft, crankpin and one counterweight are formed as a casting. A one-piece connecting rod is then slid onto the crankpin and a second counterweight is molded to the crankshaft on the side of the crankpin opposite from the cast counterweight.

Abstract: A multi-piece crankshaft having a main shaft with two ends adapted to rotate about its axis. A crankpin also has two ends and an axis parallel to but radially spaced from the axis of the main shaft. At least one counterweight extends between one end of the shaft and one end of the crankpin and this counterweight is formed by casting a liquid metal around the ends of the main shaft and crankpin in a molding chamber.

Abstract: A laminated counterweight for connecting the main shaft with the crankpin of a crankshaft in which the counterweight includes a pair of end laminations which are circular in shape and have a central opening dimensioned to receive the main shaft and a crankpin opening radially spaced from the central opening and dimensioned to receive the crankpin. A plurality of central laminations is sandwiched in between the end laminations. Each central lamination, like the end laminations, includes a central opening dimensioned to receive the main shaft as well as a crankpin opening dimensioned to receive the crankpin. A pair of cutouts is provided through each central lamination and, said cutouts being disposed on opposite sides of the radius extending between the central opening and the crankpin opening.

Abstract: A two-part electric motor shaft assembly. The assembly includes an elongated shank member which has a cavity hollowed out at one end. A cam pin has one end configured to be received in the shank cavity and secured thereto. The other end of the cam pin forms a cam surface which is eccentric with respect to a longitudinal axis defined by the elongated shank member. By utilizing a two-piece design, the shank member may be formed of a softer and less expensive material than the alloy steel used to form the cam pin since the shank member is subjected to less loading and wear. The two-part motor shaft assembly of the present invention eliminates the stress riser that occurs with application of loading to the transition joint of a single piece design.