# US 9,381,557 B2 · Method of forming integrated drive shaft and yoke

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- Number: US 9,381,557 B2
- Document ID: US9381557B2
- Status: Granted
- Kind: B2
- Application number: 14/384,783
- Filed: 2013-03-18
- Published: 2015-04-09
- Granted: 2016-07-05
- Earliest claimed: 2012-03-16
- Assignees: Szuba Consulting, Inc.; Value Extraction LLC
- Applicants: Szuba Consulting, Inc.; Value Extraction LLC
- Inventors: Joseph Szuba; Henry E. Fradkin
- Web page: https://patentgrep.com/patent/US9381557B2

## CPC

- B21C 37/16: Making tubes with varying diameter in longitudinal direction
- B21B 23/00: Tube-rolling not restricted to methods provided for in only one of groups B21B17/00, B21B19/00, B21B21/00, e.g. combined processes {planetary tube rolling, auxiliary arrangements, e.g. lubricating, special tube blanks, continuous casting combined with tube rolling}(B21B25/00 takes precedence)
- B21D 51/16: characterised by the use of the objects (making heat exchangers B21D53/02)
- B21H 1/18: cylinders, e.g. rolled transversely {cross-rolling}
- B21K 1/12: of specially-shaped cross-section
- B60K 17/22: characterised by arrangement, location, or type of main drive shafting, e.g. cardan shaft
- B21C: MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21B: ROLLING OF METAL (auxiliary operations used in connection with metal-working operations covered in B21, see B21C; bending by rolling B21D; manufacture of particular objects, e.g. screws, wheels, rings, barrels, balls, by rolling B21H; pressure welding by means of a rolling mill B23K20/04)
- B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F)
- B21H: MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS (essentially from sheet metal B21D)
- B21K: MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS (making particular articles by working sheet metal without essentially removing material B21D; processing wire B21F; making pins, needles or nails B21G; making particular articles by rolling B21H; forging machines, pressing machines, hammering machines, in general B21J; making chains B21L; plating B23K)
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES

## Abstract

A method of forming a shaft for transferring force from a driving element to a driven element makes use of a tube. The tube is deformed to define distal ends of said shaft. At least one of the distal ends of the tube is trimmed to define a yoke for engaging one of the driving element or the driven element, with the yoke being integrally formed with the shaft.

## Claims

### Claim 1

A method of forming a shaft for transferring force from a driving element to a driven element, the method comprising:
deforming a tube to define distal ends of said shaft, said tube having a wall thickness;
folding a portion of at least one of said distal ends onto itself to establish a flange, said at least one of said distal ends having an increased thickness that is greater than said wall thickness; and
trimming said at least one of said distal ends to define a yoke for engaging one of the driving element or the driven element, said yoke comprising a portion of said flange and being integrally formed with said shaft.

### Claim 2 (depends on 1)

The method set forth in claim 1, wherein said trimming includes forming opposing ears each having an aperture for receiving a pin for attaching said shaft to one of the driving element or the driven element.

### Claim 3 (depends on 1)

The method set forth in claim 1, wherein said deforming includes forming a plurality of shafts from said tube, seriatim.

### Claim 4 (depends on 1)

The method set forth in claim 1, wherein said deforming includes reducing a diameter of the tube between said distal ends of said shaft.

### Claim 5 (depends on 1)

The method set forth in claim 1, including forming ribs along said shaft between said distal ends of said shaft thereby strengthening said shaft.

### Claim 6 (depends on 5)

The method set forth in claim 5, wherein forming said ribs includes forming ribs along an inner wall of said shaft.

### Claim 7 (depends on 1)

The method set forth in claim 1, wherein said deforming includes roll forming said tube between said distal ends of the shaft for increasing work hardening and for elongating the grain of the tube for strengthening said shaft.

### Claim 8 (depends on 1)

The method set forth in claim 1, wherein said deforming includes decreasing the wall thickness of a section of the tube between said distal ends of said shaft.

### Claim 9 (depends on 1)

The method set forth in claim 1, wherein said trimming includes trimming both distal ends of the tube to define opposing yokes of said shaft.

### Claim 10 (depends on 1)

The method set forth in claim 1, wherein said trimming includes trimming one distal end of the tube to define a yoke and forming an opposing distal end of the tube for receiving a mating tube for providing a collapsible shaft.

### Claim 11 (depends on 1)

The method set forth in claim 1, further including sealing at least one said distal end of said shaft using a seal inside of said shaft.

### Claim 12 (depends on 1)

The method set forth in claim 1, wherein said folding includes manipulating a material of said at least one distal end to establish said flange on an outer surface of said at least one distal end.

### Claim 13 (depends on 1)

The method set forth in claim 1, wherein said folding includes manipulating a material of said at least one distal end to establish said flange on an inner surface of said at least one distal end.

### Claim 14 (depends on 1)

The method set forth in claim 1, wherein said increased thickness is approximately twice said wall thickness.