Plastic shafts with molded core and external feature
AssigneeXerox Corporation
InventorROBERT D. RUSSELL
Life of this patent
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Abstract
A shaft assembly including an elongated member having at least a portion which is hollow having an inside surface defining a shaft core is provided. The shaft assembly includes a rotatable, torque transmitting elongated member defining a portion thereof which is hollow having an inside surface and defining a shaft core. The shaft has an outside surface including a torque transmitting portion and a functional feature portion. The elongated member defines an aperture gate extending from the inside surface to the outside surface. The elongated member also defines a hardened, moldable material. The material extends from the inside surface through the aperture gate. The material is secured to at least a portion of the outside surface.
Claims21
A shaft assembly comprising:
- a rotatable, torque transmitting elongated member defining a portion thereof which is hollow having an inside surface defining a shaft core, said shaft having an outside surface including a torque transmitting portion and a functional feature portion, said elongated member defining an aperture gate extending from the inside surface to the outside surface;
- and
- a hardened, moldable material, said material extending from the inside surface through the aperture gate, the material secured to at least a portion of the outside surface.
An apparatus comprising mechanical components capable of performing at least one operation requiring the use of a shaft assembly, said shaft assembly comprising:
- a rotatable, torque transmitting elongated member defining a portion thereof which is hollow having an inside surface defining a shaft core, said shaft having an outside surface including a torque transmitting portion and a functional feature portion, said elongated member defining an aperture gate extending from the inside surface to the outside surface;
- and
- a hardened, moldable material, said material extending from the inside surface through the aperture gate, the material secured to at least a portion of the outside surface.
A process for making a rotatable shaft assembly for transmitting torsional torque having at least one functional feature on an outside surface of said shaft, the process comprising the steps of:
- gas injection molding an elongated member having at least a portion which is hollow having an inside surface defining a shaft core and an outside surface defining a shaft functional surface;
- providing the elongated member with an aperture gate extending from the inside surface to the outside surface;
- placing the hollow portion in a mold which has a cavity for the at least one functional feature on the outside surface of said portion;
- filling the mold with a hardenable, moldable material, flowing the moldable material through the shaft core and cavity;
- permitting the moldable material to harden to form the functional feature;
- and
- removing the shaft assembly with the functional feature from the mold.
Dependencies are inferred from the claim text.