Universal joint with reinforced yoke ears and positively locked trunnions

A universal joint for connecting first and second torque transmitting shafts, the universal joint comprising:

• a central body having first and second opposite apertures through which a first reference axis is defined and third and fourth opposite apertures through which a second reference axis is defined;
• a first yoke portion that is configured to be secured to a first torque transmitting shaft, wherein the first yoke portion includes first and second spaced opposite ears that are respectively disposed over the first and second opposite apertures;
• first and second opposite trunnions that are respectively inserted through the first and second ears of the first yoke portion and the first and second apertures of the central body to secure the first yoke portion to the central body for pivoting about the first reference axis;
• a second yoke portion that is configured to be secured to a second torque transmitting shaft, wherein the second yoke portion includes first and second spaced opposite ears that are respectively disposed over the third and fourth opposite apertures;
• third and fourth opposite trunnions that are respectively inserted through the first and second ears of the second yoke portion and the third and fourth apertures of the central body to secure the second yoke portion to the central body for pivoting about the second reference axis;
• and
• a locking assembly disposed within the central body and secured to the first, second, third and fourth trunnions to inhibit movement thereof along the first and second reference axes, respectively, wherein a head of each of the first and second trunnions includes a surface that contacts a lower surface of a corresponding depression formed on an outer surface of the first yoke portion to inhibit movement of the first and second ears of the first yoke in first and second opposite direction along the first reference axis, and wherein a head of each of the third and fourth trunnions includes a surface that contacts a lower surface of a corresponding depression formed on an outer surface of the second yoke portion to inhibit movement of the first and second ears of the second yoke portion in first and second opposite direction along the second reference axis.

A method of assembling a universal joint, comprising:

• positioning first and second spaced ears of a first yoke portion over respective first and second spaced apertures of a central body;
• inserting a first trunnion through the first ear of the first yoke portion and the first aperture of the central body along a first reference axis until a non-circular perimeter of a head of the first trunnion is seated within a non circular corresponding depression with a non-circular outer perimeter formed on an outer surface of the first ear of the first yoke portion to inhibit relative rotation between the first trunnion and the first yoke portion;
• inserting a second trunnion through the second ear of the first yoke portion and the second aperture of the central body along the first reference axis until a non-circular perimeter of a head of the second trunnion is seated within a corresponding depression with a non-circular outer perimeter formed on an outer surface of the second ear of the first yoke portion to inhibit relative rotation between the second trunnion and the first yoke portion;
• positioning first and second spaced ears of a second yoke portion over respective third and fourth spaced apertures of the central body;
• inserting a third trunnion through the first ear of the second yoke portion and the third aperture of the central body along a second reference axis until a non-circular perimeter of a trunnion head of the third trunnion is seated within a corresponding depression with a non-circular outer perimeter formed on an outer surface of the first ear of the second yoke portion to inhibit relative rotation between the third trunnion and the second yoke portion, wherein the first and second reference axes are perpendicular;
• and
• inserting a fourth trunnion through the second ear of the second yoke portion and the fourth aperture of the central body along the second reference axis until a non-circular perimeter of a trunnion head of the fourth trunnion is seated within corresponding depression with a non-circular outer perimeter formed on an outer surface of the second ear of the second yoke portion to inhibit relative rotation between the fourth trunnion and the second yoke portion;
• and
• inserting a locking apparatus into central body and into contact with the first and second trunnions to inhibit movement of the first and second trunnions along the first reference axis while allowing for rotation of the first trunnion, second trunnion, and first yoke portion about the first reference axis relative to the locking member.