Axle assembly and method of manufacture i'hereof

An axle assembly comprising:

• an axle having a first geometric shape housed within an axle housing having a second geometric shape;
• a shock absorber between the axle and the axle housing, the shock absorber comprises one or more flexible components, each of the one or more flexible components comprising a first lateral side, a second lateral side, and an inner side, the shock absorber supporting the axle within the axle housing, the first geometric shape and the second geometric shape comprising polygons;
• the one or more flexible components further comprising:
• a rigid material comprising a 60-80 Shore D material, at least a portion of the rigid material in contact with the axle when assembled;
• a first material comprising a 55-75 Shore A material, the first material supported by the rigid material;
• and
• a slip coat supported by the first material, the slip coat covering at least one of the first lateral side and the second lateral side comprising the first material, the first lateral side and the second lateral side in contact with the axle housing when assembled.

A method of manufacturing an axle assembly comprising the steps of:

• providing an axle housing for positioning an axle within an internal opening surrounded by at least one wall;
• providing an axle that is inserted into said axle housing;
• positioning a shock absorber between said axle and said axle housing;
• forming the shock absorber from one or more flexible components, each of the one or more flexible components comprising a lateral side and an inner side, the one or more flexible components comprising a rigid material extending along at least a portion of the inner side, the shock absorber supporting the axle within the axle housing, the inner side in contact with the axle;
• the one or more flexible components further comprising a first material having a first elasticity value and the rigid material having a second elasticity value wherein said first elasticity value is not equal to said second elasticity value;
• and
• applying a coating along at least a portion of said first material such that at least a portion of said coating is in contact with said axle housing when assembled.