Abstract: A method of manufacturing a driveshaft for use in a vehicular drive train system includes the initial step of providing an inner tube including a portion having a plurality of splines formed therein. A portion of an outer tube is then disposed about the portion of the inner tube in an overlapping or telescoping manner, preferably in a press fit relationship. Next, portions of the outer tube are deformed radially inwardly about the inner tube. The radially inwardly deformed portions of the outer tube that extend between the external splines of the inner tube define internal splines on the outer tube. The internal splines formed on the outer tube cooperate with the external splines formed on the inner tube to provide a rotational driving connection between the inner tube and the outer tube, while normally preventing relative axial movement therebetween.

Abstract: An axially collapsible driveshaft includes a first driveshaft tube section, a connecting member having a first end portion that is secured to the first driveshaft tube section, and a second driveshaft tube that is secured to a second end portion of the connecting member. During normal operation of the drive train assembly, torque is transmitted through the driveshaft by means of the securement between the first driveshaft tube section, the connecting member, and the second driveshaft tube section. However, if a relatively large axial force is applied to the end portions of the driveshaft, either or both of the end portions of the connecting member are designed to fracture, allowing relative axial movement to occur between the first driveshaft tube section and the second driveshaft tube section. An annular recess may be formed in the connecting member adjacent to either or both of the end portions that are secured to the driveshaft tube sections.

Abstract: A method of manufacturing a collapsible driveshaft assembly includes the steps of disposing an end of a first tube within a forming die having a non-circular cross sectional shape, expanding the end of the first tube into conformance with the die cavity, inserting an end of a second tube is inserted within the deformed end of the first tube, and expanding the end of the second tube into conformance with the end of the first tube. As a result of this expansion, outwardly extending regions and inwardly extending regions of the second tube extend into cooperation with outwardly extending regions and inwardly extending regions of the first tube so as to cause the first and second tubes to function as cooperating male and female splined members. As a result, a rotational driving connection therebetween to form the driveshaft. When a relatively large axial force is applied to the ends of the telescoping driveshaft, the second tube will move axially within the first tube, thereby collapsing and absorbing energy.

Abstract: A flexible boot assembly for protectively covering a constant velocity joint includes a flexible boot having an end portion that is molded about a flange portion of a rigid can. The flexible boot is preferably formed from an elastomeric material and can be integrally molded to a metallic can by an insert molding or other similar process. The metallic can includes a hollow cylindrical flange portion for positioning the can with respect to the constant velocity joint. The metallic can also includes a face portion having a plurality of apertures formed therethrough for mounting the boot assembly to the constant velocity joint. The inner surface of the metallic can includes a bead of a sealing material or a gasket for sealingly engaging the boot assembly to the adjacent face of the constant velocity joint. In another embodiment, the entire boot assembly is formed by using elastomeric material. In alternative embodiments, the entire boot assembly is formed from an elastomeric material.

Abstract: A flexible boot assembly for protectively covering a constant velocity joint includes a flexible boot having an end portion that is molded about a flange portion of a rigid can. The flexible boot is preferably formed from an elastomeric material and can be integrally molded to a metallic can by an insert molding or other similar process. The metallic can includes a hollow cylindrical flange portion for positioning the can with respect to the constant velocity joint. The metallic can also includes a face portion having a plurality of apertures formed therethrough for mounting the boot assembly to the constant velocity joint. The inner surface of the metallic can includes a bead of a sealing material or a gasket for sealingly engaging the boot assembly to the adjacent face of the constant velocity joint. In another embodiment, the entire boot assembly is formed by using elastomeric material. In alternative embodiments, the entire boot assembly is formed from an elastomeric material.

Abstract: A noise reduction structure for an aluminum-based driveshaft tube includes a generally cylindrical member having a predetermined length. The noise reduction structure is disposed within a driveshaft tube in a press fit relationship with the inner surface of the tube. In general, the noise reduction structure is positioned within the driveshaft tube at a location where the amplitude of a standing wave caused by the reflection of the sound waves back and forth along the driveshaft tube is at its maximum value. The length of the noise reduction structure may be about 10% or less of the value of the length of the driveshaft tube. In a first embodiment, the noise reduction structure is formed from a polymeric foam material having a density of less than about 10 lb/ft3. Preferably, the material has a density in the range of about 2 lb/ft3 to 10 lb/ft3, and more preferably, in the range of about 3 lb/ft3 to 7 lb/ft3.

Abstract: A constant velocity joint shaft and inner race combination is provided. The combination includes a shaft having an annular shoulder and a splined section generally adjacent to the shoulder. An inner race with a splined bore is fitted over the splined section of the shaft. A retaining member is provided to connect the inner race to the shaft. The retaining member has an annular body with a plurality of tabs extending in a forward axial direction to be crimped over the shaft annular shoulder. The retaining member also includes a plurality of elongated arms. The elongated arms extend from the annular body in a rearward axial direction completely through the inner race bore. The arms have an acutely bent finger at their extreme end to axially retain the inner race on the shaft. To ease assembly, the retaining member can be pre-assembled on the shaft.

Abstract: A structure for securing a flexible boot to a face of the outer race of a constant velocity joint which includes providing the boot with a generally annular flat flange portion having a uniform thickness and a plurality of apertures formed therethrough. A securing structure includes a generally annular retaining ring having a corresponding plurality of apertures formed therethrough, with an axially extending collar portion formed about each of the apertures. The axial lengths of the collar portions are approximately 80 percent of the thickness of the boot flange. The boot is secured to the face of the outer race by disposing the retaining ring thereabout such that the collar portions extend through the boot flange apertures. Respective threaded fasteners are inserted through the retaining ring and boot flange apertures into axially extending bores formed in the outer race, which fasteners may be the way by which the joint is mounted.