Angle stop

Abstract

Constant velocity universal joint comprising an outer joint portion (270, 470, 670, 870) having an open end (294, 494, 694, 894), an outer joint axis and an outer joint inner surface which at least partially forms an inner chamber, an inner joint portion (272, 472, 672, 872) comprising a journal star (276, 476, 676, 876) arranged in the outer joint portion (270, 470, 670, 870) and a shaft (274, 474, 674, 874) extending through the open end (294, 494, 694, 894), wherein the journal star (276, 476, 676, 876) has a journal (306, 506, 706, 906) which is at least partially arranged in the chamber and the shaft (274, 474, 674, 874) forms a shaft axis, and wherein the inner joint portion (272, 472, 672, 872) comprises an angular movement limiting device which limits the angulation of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870) to prevent the shaft (274, 474, 674,874) contacts the outer joint (270, 470, 670, 870), and a bellows assembly (370, 570, 770, 970) comprising a bellows bushing (332, 532, 732, 932) and a bellows (334, 534, 734, 934), the bellows bushing (332, 532, 732, 932) having a tulip end (352, 552, 752, 952) connected to the outer joint portion (270, 470, 670, 870) and a crimped end (350, 550, 750, 950) connected to the bellows (334, 534, 734, 934), wherein the bellows (334, 534, 734, 934) has a bellows outer surface (346, 546, 746, 946) and a shaft end (342, 542, 742, 942) connected to the shaft (274, 474, 674, 874), and wherein the angling of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870) results in the limiting device contacting the outer joint portion (270, 470, 670, 870), thereby establishing contact between the bellows outer surface (346, 546, 746, 946) and a bellows bushing outer surface (356, 556, 756, 956) is prevented.

Description

Technical FieldThe disclosure relates generally to articulating joints, and more particularly to a system and method for limiting articulation of an articulating joint.BACKGROUND OF THE INVENTIONConstant velocity joints (CVJs) and other swivel joints are conventional components in motor vehicles. Constant velocity universal joints are usually used where the transmission of a constant rotary movement is necessary. Typical types of constant velocity universal joints are tripod type links, tripod type links, ball type links and ball type links. The constant velocity joints are generally life-lubricated and sealed by a sealing bellows when used on drive shafts or half shafts. Constant velocity universal joints are therefore sealed to retain the grease in the joint and to keep contaminants, such as dirt and water, away from the joint. To provide this protection, the constant velocity universal joint is normally enclosed at the open end of an outer part by a sealing bellows made of rubber, thermoplastic or silicone materials. The opposite end of the outer member is generally closed by a hood or cap known as a grease cap in disc joints. A monoblock or joint designed as an integral shaft-hub joint is sealed by the internal geometry of the outer part. Sealing and protection of the constant velocity universal joint are necessary since contamination of the inner chamber of the joint generally results in damage to the joint.A primary function of the constant velocity universal joint is the transmission of rotational forces and torques. A sliding joint transmits rotational speeds while permitting relative axial displacement within the joint. Generally, a tripod joint functions as a sliding constant velocity joint, allowing a slight axial deflection. In typical hinge arrangements, various screwable joints are used to mount them on a propeller shaft or a half shaft (side shaft) in the motor vehicle. These propeller shaft and half shaft assemblies are conventionally assembled prior to installation within a powertrain of a vehicle.When a propeller shaft is mounted in a vehicle, the maximum angle between the ends of the individual joints is limited by other components of the powertrain and the vehicle. Before an assembled propeller shaft is installed in a vehicle, the individual joints may be placed in various positions that include angles between the ends of the individual joints that exceed the maximum angles that prevail during operation. Excessive position may result in arrangements of the individual joints, causing damage to components such as the hinge bellows. Importantly, the boot of a tripod joint is incorporated into a propeller shaft in which the geometry of the tripod joint allows the shaft of the tripod joint to clamp a portion of the flexible boot, thereby potentially damaging the boot and reducing the expected life of the boot. There is therefore a need for a system for limiting the deflection (non-axial angular rotation of the shaft) of a tripod joint or other joints to prevent damage to the boot prior to and during installation of the propeller shaft.Disclosure of the InventionThe present application discloses a hinge device having an outer hinge portion having an open end, an outer hinge axis, and an outer hinge inner surface that at least partially forms an inner chamber. The articulation device further includes an inner articulation portion including a spider inserted into the outer articulation portion and a shaft forming a shaft axis and extending through the open end. The pin star comprises a pin. The pin is at least partially inserted into the chamber. The inner joint portion includes a deflection limiting device that limits the deflection of the joint.Brief Description of the DrawingsExemplary embodiments are illustrated in detail in the drawings. Although the drawings illustrate some embodiments, they are not necessarily to scale and certain features may be exaggerated, removed, or partially cut to better illustrate and explain the present invention. Furthermore, it is not intended that the embodiments illustrated herein be exhaustive or to limit or limit the claims to the precise embodiments and configurations illustrated in the drawings and disclosed in the following detailed description in any way. FIG. 1 is a top view of a powertrain system. FIG. 2 is a partially cut-away plan view of the propeller shaft shown in FIG. 1. FIG. 3 is a partially cut-away view of a portion of the propeller shaft of FIG. 2. FIG. 4 is an exploded perspective view of a portion of a propeller shaft of FIG. 2. FIG. 5 is a cross-sectional view taken along dashed line 5- 5 of FIG. 3, with some portions removed for purposes of clarity. FIG. 6 is a partially cut-away view of a portion of a propeller shaft according to the prior art. FIG. 7 is a partially cut-away view of a portion of a propeller shaft. FIG. 8 is a partially cut-away view taken along section line 8-8 of FIG. 7. FIG. 9 is a partially cut-away view of a portion of a propeller shaft. FIG. 10 is a sectional view of the portion of a propeller shaft. FIG. 11 is a partially cut-away view of a portion of a propeller shaft. FIG. 12 is a partially cut-away view of a portion of a propeller shaft. FIG. 13 is a cross-sectional view of the portion of the propeller shaft of FIG. 12 illustrating a second position. FIG. 14 is a cross-sectional view taken along section line 14- 14 of FIG. 12.Detailed DescriptionFIG. 1 shows a powertrain 20 of a vehicle (not shown). The drive train 20 comprises an engine 22 connected to a transmission 24 and an output unit 26. A front differential 32 includes a right front half shaft 34 and a left front half shaft 38 each connected to a wheel 38 and supplying power to these wheels. The output unit 26 includes a propeller shaft 40 and a front wheel propeller shaft 42 extending therefrom. The front steering shaft 42 connects the front differential 32 to the output unit 26 The longitudinal drive shaft 40 connects the output unit 26 to a rear differential 44, the rear differential 44 including a rear right side shaft 46 and a rear left side shaft 48 each terminating at one end at a wheel 38.The longitudinal drive shaft 40 includes, as best seen in FIG. 2, a front propeller shaft 52, a rear propeller shaft 54, a tripode knuckle 50 that can be angled, and two high speed constant velocity universal joints 60. the front propeller shaft 52 is defined by an axis A-A and the rear propeller shaft 54 is defined by an axis B-B. The constant velocity joints 60 transmit power even when the wheels 38 or shafts have varying angles due to suspension steering and rebound. Constant velocity joints 60 are also disposed at both ends of the half shafts 46, 48 which connect the wheel 38 to the rear differential 44. Also, both ends of the right front half shaft 34 and the left front half shaft 36 include constant velocity universal joints 60.Constant velocity joints 60 may be represented by any standard types, including, for example, tripod type slip joints, cross track joints, ball type fixed joints, tripod type fixed joints, or double offset joints, all of which are well known terms in the art of various types of constant velocity joints. The constant velocity joints 60 allow transmission of constant velocities at angles which occur during the common driving of motor vehicles in both the half shafts (side shafts) and longitudinal shafts of these vehicles.The powertrain 20 is an all-wheel-drive vehicle, but it should be noted that the embodiment of the constant velocity universal joints 60 according to the present invention may also be used with rear-wheel drive vehicles, front-wheel drive vehicles, all-wheel drive vehicles, and four-wheel drive vehicles.As best seen in Figs. 3-5, the hinge 50 includes a tulip or outer hinge portion 70 connected to the front hinge shaft 52 and an inner hinge portion 72. The inner joint portion 72 also includes a tripod or spider 76 splined to the shaft 74. As best seen in FIG. 2, the tulip 75 is further generally defined by the axis A-A of the front propeller shaft 52 and the shaft 74 is further generally defined by the axis B-B of the rear propeller shaft 54.The tulip 70 is provided with an internal recess 84 which has three chambers 86 distributed uniformly over the circumference. The chambers 86 form pairs of circumferentially opposed tracks 88 which are joined by a chamber major surface 90 which extends from an open end 94 of the tulip 70 to an annular wall 96. The webs 88 of the adjacent chambers 86 are joined by a tulip minor surface 92. The spider 76 includes an annular hub portion 100 provided with an aperture 102 for insertion of the shaft 74 therein and three equally circumferentially spaced trunnion bosses 104. As shown, the spider 76 is splined to the shaft 74 for rotation therewith. Three circumferentially distributed pins 106 having axles T1, T2, T3 and a pin crown 108 at a free end extend from the hub portion 100 (at each pin boss 104). A pin 106 is inserted into each chamber 86. A roller unit 110 is disposed in each chamber 86 with a pin 106 inserted therein. Each pin 106 includes a pin groove 112 formed therein. Each roller unit 110 includes support needles 116 and a roller 118.Each roller 118 with bearing needles 116 is axially fixed to each pin 106 by a retainer disc 120 and a circlip 122. The retaining ring 122 is fixed in a pin groove 112 of each pin 106. In conjunction with the retainer disc 120, the snap ring 122 secures each bearing needle 116 and roller 118 to each pin 106. The roller units 110 may float axially along the axes T 1, T 2, T 3 between contact with the pin bosses 104 and the snap rings 120. Generally, the chamber major surface 90 is formed by a first chamber diameter dv, and the tulip minor surface 92 is formed by a second chamber diameter dv (FIG. 5 ). Each pin 106 includes a cylindrical outer surface 124 and a pin end 126. When the pin star 76 is concentric with the tulip 70, a gap C is generally provided between each pin end 126 and the chamber major surface 90 (FIGS. 3 and 5 ).As best shown in FIG. 5, the hinge 50 can be divided about the axes A-A and B-B into three generally equal sections. Each pin is generally defined by a pin radius TH extending to the pin end 126. When the joint 50 is drivingly connected to the tulip 70 and the shaft 74 is generally axially aligned, the rotational forces within the joint 50 act to coaxially align the axes A-A and B-B and to float within the roller units 110 to provide a generally uniform gap C between each pin end 126 and the chamber major surface 90. That is, generally, the journal radius TH added with the gap C corresponds to the first chamber diameter DV.As best seen in FIG. 3, the hinge 50 further includes a bellows assembly 130. The bellows assembly 130 includes a bellows sleeve 132 and a flexible bellows 134. The flexible bladder 134 includes an outer end bead 140, an inner shaft end 142, a flexible portion 144 extending therebetween, a bladder outer surface 146, and a bladder inner surface 148. The bellows sleeve 132 includes a crimped end 150 folded back over the end bead 140, a tulip end 152 connected to the tulip 70, a generally cylindrical sleeve body 154 extending therebetween, a sleeve outer surface 156, and a sleeve inner surface 158.FIG. 6 shows the articulated shaft of FIGS. 1-5 in an arrangement according to the prior art, wherein identical components have identical reference numerals. In the prior art arrangement, the axis A-A of the front tulip 70 is not aligned with the axis B-B of the shaft 74. In the illustrated position, the hinge 50 cannot rotate when installed in the powertrain 20 in the prior art arrangement, but can only be angled to the prior art configuration when not fully mounted in the powertrain 20 because the angle of a mounted hinge 50 is not limited prior to installation. When fully installed in the powertrain 20, the joint 50 may be angled as it is limited by the positioning of the shafts 52, 54 relative to a third configuration (not shown), i.e., in an intermediate position between the axial orientation of FIG. 3 and the unobstructed angle of FIG. 6 That is, operation of the powertrain 20 will not cause contact of the powertrain components, such as contact between the shaft 74 and the front tulip 70, and generally the joints, such as joint 50, are dimensionally configured such that this contact is not caused at a maximum angle allowed by the powertrain 20 and by the components of the powertrain 20 generally attached to the vehicle.As best seen by comparing FIGS. 3 and 6, the gap C between each pin end 126 and the chamber main surface 90 allows the shaft 74 to be angled relative to the tulip 70. However, Figure 6 shows that shaft 74 can be angled relative to tulip 70 until sleeve outer surface 156 of crimped end 150 of bladder sleeve 132 contacts bladder outer surface 146 of bladder 134. This contact may result in damage to the bellows 134 and including failure of the bellows 134 with respect to its desired operation. The damage detected includes undesirable cracked portions of the bellows 134.FIGS. 3 and 6 also show that the tulip 70 can be displaced axially relative to the shaft 74. When the hinge 50 is not fully installed, this relative axial displacement is limited by the contact between the shaft 74 and / or the spider 76 and the wall 96 in a fully inserted shaft assembly (not shown) and expansion of the bellows 134 in a fully extended shaft assembly (not shown). Damage to the bellows may occur at various extension positions between the tulip 70 and the shaft 74 between the fully inserted shaft position and the fully extended shaft position when the hinge 50 is not fully installed. When fully assembled (FIG. 1 ), the travel of the joint 50 includes relative axial displacement between the shaft 74 and the tulip 70 that is not limited by contact or interference between the components of the joint 50. That is, when fully installed in the powertrain 20, the hinge 50 is constrained by other components of the powertrain 20 and therefore cannot be shifted to the full-wave position or the shaft-out position.FIG. 7 shows a joint 250. The hinge 250 includes a tulip or outer hinge portion 270 connected to a front hinge shaft, such as the front hinge shaft 52, and an inner hinge portion 272. The inner hinge portion 272 includes a shaft 274 that is connected to a rear hinge shaft, such as the rear hinge shaft 54. The inner joint portion 272 also includes a tripod or spider 276 splined to the shaft 274. The tulip 270 is generally defined by an axis A1-A1and the shaft 274 is defined by an axis B1-B1. The tulip 270 may be axially displaced relative to the shaft 274 during operation of the powertrain 20 and at other times including transportation and assembly of a propeller shaft, such as the propeller shaft 40.The tulip 270 is provided with an internal recess 284 having three circumferentially evenly distributed chambers 286. The chambers 286 form pairs of circumferentially opposed tracks 288 joined by a first inner surface or chamber major surface 290 extending from an open end 294 of the tulip 270 to an annular wall 296. The webs 288 of adjacently disposed chambers 286 are joined by a second inner surface or tulip minor surface 292. Spider 276 includes an annular hub portion 300 which is provided with an opening 302 for insertion of shaft 274 and three equally circumferentially spaced trunnion bosses 304. As shown, the spider 276 is splined to the shaft 274 for rotation therewith. Three circumferentially spaced pins 306 having a pin crown 308 at a free end extend (at each pin boss 304) from the hub 300.Each pin 306 is disposed in one of the chambers 286. A roller unit 310 having a pin 306 disposed therein is disposed in each chamber 286. Each roller unit 310 includes support needles 316 and rollers 318. Each roller 318 with bearing needles 316 is axially fixed on a pin 306 by a circlip 320. The roller units 310 may axially float between contact with the pin bosses 304 and the snap rings 320.Generally, the chamber major surface 290 is formed by a first chamber diameter DV, and the tulip minor surface 292 is formed by a second chamber diameter dv (as shown in FIG. 5). Each pin 306 includes a generally cylindrical outer surface 324 and a pin end 326. That is, each pin 306 is formed by a generally cylindrical surface extending between a pin boss 304 and a pin crown 308, where the pin crown 308 has the pin end 326. When the pin star 276 is concentric with the tulip 270, a gap is generally provided between each pin end 326 and the chamber major surface 290. The gap between each pin end 326 and the chamber main surface 290 allows the shaft 274 to be angled relative to the tulip 270.Figure 8 shows the hinge 250 with the spider 276 removed and the shaft 274 centered therein for clarity. As best seen in FIG. 8, the hinge 250 can be divided about the axes A1-A1and B1-B1into three generally equal sections. When the joint 250 operates with the tulip 270 and the shaft 274 is generally axially aligned, the rotational forces within the joint 250 urge the axes A1-A1and B1-B1to align coaxially and the pins float in the roller units 310 to provide a generally uniform gap between each pin end 326 and the chamber main surface 290.Referring again to FIG. 7, the hinge 250 further includes a bellows assembly 330. Bellows assembly 330 includes bellows sleeve 332 and flexible bellows 334. Flexible bladder 334 includes an outer end bead 340, an inner shaft end 342, a flexible portion 344 extending therebetween, a bladder outer surface 346, and a bladder inner surface 348. The bellows sleeve 332 includes a crimped end 350 folded back over the end bead 340, a tulip end 352 connected to the tulip 270, a generally cylindrical sleeve body 354 extending therebetween, a sleeve outer surface 356, and a sleeve inner surface 358.FIGS. 7 and 8 show that the joint 250 further comprises a limiting device or limiting portion 360. In the illustrated embodiment, the restraining portion 360 is generally a ring having an annular inner surface 364 (FIG. 8 ) generally attached (keyed or crimped) to the shaft 274 and a generally cylindrical outer restraining surface 368. In FIG. 7, the axis A 1-A 1 of the front tulip 270 is not aligned with the axis B 1-B 1 of the shaft 274 and the outer boundary surface 368 of the boundary portion 360 contacts the tulip minor surface 292. While the outer boundary surface 368 of the boundary portion 360 contacts the tulip minor surface 292, the pin end 326, shown in section in FIG. 7, does not contact the chamber major surface 290 in the illustrated embodiment. As best seen in Figure 8, the outer boundary surface 368 of the boundary portion 360 may contact two tulip minor surfaces 292 when the shaft 274 is angled in the direction of arrow D8. Accordingly, a deflection between the shaft 274 and the tulip 270 is prevented when the outer boundary surface 368 of the boundary portion 360 at least partially contacts a tulip minor surface 292.The contact between the restriction portion 260 and the tulip 270 therefore prevents the sleeve outer surface 356 of the crimped end 350 of the bellows sleeve 332 from contacting the bellows outer surface 346 of the bellows 334 during the angling of the shaft 274 relative to the tulip 270. This lack of contact between crimped end 350 and bladder outer surface 346 prevents undesired damage to bladder 334.If the propeller shaft, such as the propeller shaft 40, is connected to a joint 250, manipulation of the propeller shaft, if not fully installed in the drive train 20, will not result in damage to the bellows 334 by the bellows bushing 332. The outer boundary surface 368, although shown generally cylindrical, may be curved or generally circular or any other suitable shape.FIG. 9 shows a hinge 450. The hinge 450 includes a tulip or outer hinge portion 470 connected to a front hinge shaft, such as the front hinge shaft 52, and an inner hinge portion 472. The inner hinge portion 472 includes a shaft 474 connected to a rear hinge shaft, such as the rear hinge shaft 54. The inner joint portion 472 further includes a tripod or spider 476 splined to the shaft 474. The tulip 470 is generally formed by an axis A2-A2and the shaft 474 is formed by an axis B2-B2. The tulip 470 can be axially displaced relative to the shaft 474.The tulip 470 is provided with an internal recess 484 which has three circumferentially evenly distributed chambers 486. The chambers 486 form pairs of circumferentially opposed tracks 488 which are joined by a chamber major surface 490 which extends from an open end 494 of the tulip 470 to an annular wall 496. The sheets 488 of adjacently disposed chambers 486 are connected by a tulip minor surface 492. The spider 476 includes an annular hub portion 500 provided with an opening 502 for insertion of the shaft 474 and three equally circumferentially spaced trunnion bosses 504. Three circumferentially evenly distributed studs 506 extend from the hub 500. A pin 506 is disposed in each chamber 486. A roller assembly 510 is disposed in each chamber 486 with a pin 506 received therein. Each roller unit 510 includes support needles 516 and a roller 518. Each roller 518 is axially fixed to the bearing needles 516 on each pin 506 by a circlip 520.Each pin 506 includes a cylindrical outer surface 524 and a pin end 526. When the pin star 476 is concentric with the tulip 470, a gap is generally provided between each pin end 526 and the chamber main surface 490. The gap between each pin end 526 and the chamber main surface 490 allows the shaft 474 to be angled relative to the tulip 470.The hinge 450 further includes a bellows assembly 530. The bellows assembly 530 includes a bellows sleeve 532 and a flexible bellows 534. Flexible bladder 534 includes an outer end bead 540, an inner shaft end 542, a flexible portion 544 extending therebetween, a bladder outer surface 546, and a bladder inner surface 548. Bellows sleeve 532 includes crimped end 550 folded back over end bead 540, tulip end 552 connected to tulip 470, generally cylindrical sleeve body 554 extending therebetween, and sleeve outer surface 556.The hinge 450 further includes a limiting portion 560. As shown in FIG. 9, the restraining portion 560 is a ring having a generally cylindrical outer restraining surface 568 secured to the shaft 474. The restraining portion 560 extends from the shaft 474 between the spider 476 and the wall 496, although the restraining portion 560 may be disposed between the spider 476 and the open end 494. As shown, the axis A 2-A 2 of the tulip 470 is not aligned with the axis B 2-B 2 of the shaft 474 and the outer perimeter surface 568 of the perimeter portion 560 contacts the tulip minor surface 492. Although the outer boundary surface 568 of the boundary portion 560 is in contact with the tulip minor surface 492, the pin end 526 may also contact the chamber major surface 490. The angling of the shaft 474 relative to the tulip 470 is interrupted when the outer periphery 568 of the periphery 560 is in contact with the tulip minor surface 492 and when a pin end 526 is eventually in contact with the chamber major surface 490.Therefore, the contact between the restriction portion 560 and the tulip 470 prevents the crimped end 550 of the bladder sleeve 532 from contacting the bladder outer surface 546 of the bladder 534 during the angling of the shaft 474 relative to the tulip 470. The lack of contact between crimped end 550 and bellows outer surface 546 prevents undesirable damage to bellows 534.If the propeller shaft, such as the propeller shaft 40, is connected to a joint 450, manipulation of the propeller shaft, if not fully installed in the drive train 20, will not result in damage to the bellows 534 by the bellows bushing 532. The outer boundary surface 568, although shown generally cylindrical, may be curved or generally circular or any other suitable shape.Figure 10 shows, as an alternative to the limiting portion 560, a limiting portion 600 attached to the hinge 450, with the pin star 476 removed for simplicity and the shaft 474 centered in the tulip 470. The restraining portion 600 includes three generally equally circumferentially spaced cams 610, each having a free cam diameter surface 612 and two opposing surfaces 614 forming a pair. The cams 610 are separated by three proximal diameter surfaces 616. As shown generally centered in the hinge 450, the cams 610 extend from the boundary portion 600 to the chamber main surface 490 with a gap C 4 between the chamber main surface 490 and the free cam diameter surface 612. Further, a gap C 5 measured generally radially to the axis B 2-B 2 is provided between the tulip minor surface 492 and the proximal diameter surfaces 616. The chamber major surface 490 is generally defined by a first chamber diameter dvand the tulip minor surface 492 is defined by a second chamber diameter dv(as shown in FIG. 10). The free cam diameter surfaces 612 further define an outer cam diameter DL and the proximal diameter surfaces 616 define a proximal diameter DP. As shown, the first chamber diameter DV is greater than the outer cam diameter DL, which is greater than the second chamber diameter dv, which is greater than the proximal diameter DP.In operation, the limiting portion 600 limits the angular displacement of the tulip 470 relative to the shaft 474. As the angling of the tulip 470 relative to the shaft 474 moves the restrictor in direction D2 relative to at least a portion of the tulip 470, the chamber main surface 490 contacts the free cam diameter surface 612, thereby preventing further angling. As the angling of the tulip 470 relative to the shaft 474 moves the restriction device in direction D 1, the tulip minor surface 492 contacts the proximal diameter surfaces 616, thereby preventing further angling. As in the example of FIG. 7, when the tulip 270 is angled relative to the shaft 274 where the restriction portion 360 prevents contact between the bladder sleeve 332 and the bladder 334, the restriction device 600 prevents damage to the bladder 534 when installed in a hinge 450.Although the restrictor 600 is shown disposed between the spider 476 and the wall 496 (between the spider 476 and a front propeller shaft, such as the propeller shaft 52), the restrictor 600 may be disposed between the spider 476 and the open end 494 (between the spider 476 and a rear propeller shaft, such as the rear propeller shaft 54).FIG. 11 shows another embodiment of a joint 50, as joint 650. The hinge 650 includes a tulip or outer hinge portion 670 connected to a front hinge shaft, such as the front hinge shaft 52, and an inner hinge portion 672. The inner hinge portion 672 includes a shaft 674 connected to a rear hinge shaft, such as the rear hinge shaft 54. The inner joint portion 672 further includes a tripod or spider 676 splined to the shaft 674. The tulip 670 is generally defined by an axis A3-A3and the shaft 674 is defined by an axis B3-B3. The tulip 670 can be axially displaced relative to the shaft 674.The tulip 670 is provided with an internal recess 684 which has three chambers 686 distributed uniformly over the circumference. The channels 686 form pairs of circumferentially opposed tracks 688 joined by a channel main surface 690 extending from an open end 694 of the tulip 670 to an annular wall 696. The tracks 688 of adjacently disposed channels 686 are joined by a tulip minor surface 692. The spider 676 includes an annular hub portion 700 provided with an opening 702 for insertion of the shaft 674 and three circumferentially spaced trunnion bosses 704. Three circumferentially evenly distributed studs 706 extend from the hub 700. Each pin 706 is disposed in a chamber 686. A roller unit 710 having a pin 706 disposed therein is inserted into each chamber 686. Each roller unit 710 includes support needles 716 and a roller 718. Each roller 718 with bearing needles 716 is axially locked onto the pin 706 by a snap ring 720.Each pin 706 includes a pin end 726. When the pin star 676 is concentric with the tulip 670, a gap is generally provided between each pin end 726 and the chamber major surface 690. The gap between each pin end 726 and the chamber main surface 690 allows the shaft 674 to be angled relative to the tulip 670.The hinge 650 further includes a bellows assembly 730. The bellows assembly 730 includes a bellows sleeve 732 and a flexible bellows 734. Flexible bladder 734 includes an outer end bead 740, an inner shaft end 742, a flexible portion 744 extending therebetween, a bladder outer surface 746, and a bladder inner surface 748. The bellows sleeve 732 includes a crimped end 750 folded back over the end bead 740, a tulip end 752 connected to the tulip 670, a generally cylindrical sleeve body 754 extending therebetween, and a sleeve outer surface 756.Further, the hinge 650 includes a pair of limiting portions 760, 762. In the illustrated embodiment, the end stop portions 760, 762 are rings having generally cylindrical outer end stops 770, 768, respectively, which are secured to the shaft 670. In the illustrated embodiment, the axis A 3-A 3 of the tulip 670 is not aligned with the axis B 3-B 3 of the shaft 674 and the outer perimeter surface 770 of the perimeter portion 760 contacts the tulip minor surface 692.Because the shaft 674 is not axially rotated relative to the tulip 670, the limiting surface 770 of the limiting portion 760 rotates toward the tulip minor surface 692. Further, when the outer boundary surface 768 of the boundary portion 762 or the outer boundary surface 770 of the boundary portion 760 contacts the tulip minor surface 692, the pin end 726 may contact the chamber main surface 690. The angling between the shaft 674 and the tulip 670 is interrupted when the outer boundary surface 768, 770 of the boundary portion 762, 760 contacts the tulip minor surface 692 or when a pin end 726 contacts the chamber major surface 690.Therefore, contact between one of the limiting portions 760, 762 and the tulip 670 limits the angling of the shaft 674 relative to the tulip 670 and prevents the crimped end 750 of the bellows sleeve 732 from contacting the bellows outer surface 746 of the bellows 734 during the angling of the tulip 670 relative to the shaft 674. This lack of contact between crimped end 750 and bladder outer surface 746 prevents undesirable damage to bladder 734.When a propeller shaft, such as the propeller shaft 40, is connected to a joint 650, manipulation of the propeller shaft when not fully installed in the drive train 20 will not result in damage to the bellows 734 by the bellows bushing 732. Further, although the perimeter portions 760, 762 are shown generally cylindrical, they may be curved, generally circular, or any other suitable shape.FIGS. 12-14 show another embodiment of a joint 50, as joint 850. The hinge 850 includes a tulip or outer hinge portion 870 connected to a front hinge shaft, such as the front hinge shaft 52, and an inner hinge portion 872. The inner hinge portion 872 includes a shaft 874 connected to a rear hinge shaft, such as the rear hinge shaft 54. The inner joint portion 872 further includes a tripod or pin star 876 splined to the shaft 874. The tulip 870 is generally defined by an axis A4-A4and the shaft 874 by an axis B4-B4. The tulip 870 can be axially displaced relative to the shaft 874 during operation of the powertrain 20 and at other times including transportation and assembly of a propeller shaft, such as the propeller shaft 40.The tulip 870 is provided with an internal recess 884 which has three chambers 886 distributed uniformly on the circumference. The chambers 886 form pairs of circumferentially opposed tracks 888 joined by a first inner surface or chamber main surface 890 extending from an open end 894 of the tulip 870 to an annular wall 896. The sheets 888 of adjacently disposed chambers 886 are joined by a second inner surface or a tulip minor surface 892. The spider 876 includes an annular hub portion 900 provided with an opening 902 for inserting the shaft 874 and three circumferentially spaced pin bosses 904. As shown, the spider 876 is splined to the shaft 874 for rotation therewith. Three circumferentially distributed pins 906 having axes T1, T2, and T3 (see FIG. 14) and a pin crown 908 at a free end extend from the hub 900 at each pin boss 904.A pin 906 is disposed in each chamber 886. A roller unit 910 having a pin 906 therein is inserted into each chamber 886. Each roller unit 910 includes support needles 916 and a roller 918. Each roller 918 with bearing needles 916 is axially fixed to one of the pins 906 by a snap ring 920. The roller units 910 may axially float along the axes T 1, T 2, T 3 between contact with the pin bosses 904 and the snap rings 920. As shown, the rollers 918 contact the webs 888 at curved surfacesEach post 906 includes a generally cylindrical outer surface 924 and a post end 926. That is, each pin 906 is defined by a generally cylindrical surface extending between a pin boss 904 and a pin crown 908 where the pin crown 908 includes the pin end 926. When the pin star 876 is concentric with the tulip 870, a gap C8 is generally provided between each pin end 926 and the chamber major surface 890. The gap C8 between each pin end 926 and the chamber main surface 890 allows the shaft 874 to be angled relative to the tulip 870.As shown in FIG. 14, the hinge 850 may be divided into three uniform sections about the axes A 4-A 4 and B 4-B 4. When the joint 850 is drivingly connected to the tulip 870 and the shaft 874 is generally axially aligned, the rotational forces within the joint 850 urge the axes A4-A4 and B4-B4 to coaxially align and the pins float within the roller units 910 to provide a generally uniform gap C8 between each pin crown 908 and the chamber main surface 890.Generally, the chamber major surface 890 is formed by a first chamber diameter dv, and the tulip minor surface 892 is formed by a second chamber diameter dv (as shown in FIG. 14). The hub 900 forms an outer hub diameter DH.A pin radius DS is measured between the axis B 4-B 4 and the pin end 926. That is, the outermost portion of the pin 906 extending from the pivot point along the axis B 4-B 4 is a distance DS from the axis B 4-B 4. Accordingly, as the pin height DS is increased for a joint, such as joint 850, the maximum angular movement (measured between axis A 4-A 4 and axis B 4-B 4 of FIG. 13 ) is decreased. For example, a pin radius DS of 31.011 millimeters (mm) and a first chamber diameter DV of 62.60 mm would result in an angular movement of approximately 22 degrees. In this example, the hinge cannot be angled beyond a relative angle between axis A 4-A 4 and axis B 4-B 4 of about 22 degrees. Further, operation of this joint within a powertrain, such as powertrain 20, would not require a deflection beyond 22 degrees. In this example, the ratio of chamber diameter DV to pin radius DS would be about 2.02. The present invention finds a ratio of chamber diameter DV to pin radius DS of from about 1.95 to about 2.05 to be desirable, with a ratio of chamber diameter DV to pin radius DS of from about 1.98 to about 2.02 being more advantageous.The hinge 850 includes a bellows assembly 930. The bellows assembly 930 includes a bellows sleeve 932 and a flexible bellows 934. The flexible bladder 934 includes an outer end bead 940, an inner shaft end 942, a flexible portion 944 extending therebetween, a bladder outer surface 946, and a bladder inner surface 948. Bellows sleeve 932 includes crimped end 950 folded back over end bead 940, tulip end 952 connected to tulip 870, generally cylindrical sleeve body 954 extending therebetween, sleeve outer surface 956, and sleeve inner surface 958.Figures 12-14 show that the hinge 850 may further include a restriction portion 960. In the illustrated embodiment, the limiting portion 960 includes three outer limiting surfaces 968 formed by the pin crowns 908 and pin ends 926. The outer boundary surface 968, although shown generally cylindrical, may be curved or generally circular or any other suitable shape. FIGS. 12 and 14 show the hinge 850 in a first embodiment, wherein the axis A 4-A 4 of the front tulip 870 is generally aligned with the axis B 4-B 4 of the shaft 874.FIG. 13 shows the joint 850 in a limit position. In the limit position, the axis A4-A4 of the front tulip 870 is not aligned with the axis B4-B4 of the shaft 874 and a pin crown 908 of the limit portion 960 is in contact with the chamber main surface 890. A bend between the shaft 874 and the tulip 870 is interrupted when the outer boundary surface 968 of the pin crown 908 of the boundary portion 960 is in contact with the chamber main surface 890.The contact between the restriction portion 960 and the tulip 870 therefore prevents the sleeve outer surface 956 of the crimped end 950 of the bellows sleeve 932 from contacting the sleeve outer surface 946 of the bellows 934 during the angling of the tulip 870 relative to the shaft 874. This lack of contact between crimped end 950 and bellows outer surface 946 prevents undesirable damage to bellows 934.In the limit position shown in FIG. 13, the hub 900 is not in contact with the tulip minor surface 892, although the hub may contact the tulip minor surface in other embodiments. As shown in the limit position of FIG. 13, and with reference to FIG. 14, when the shaft 874 is rotated in direction D 13 relative to the tulip 870, the pin star 876 rotates the rollers 918, and the rollers 918 disposed on the pins 906 that form the axes T 2 and T 3 limit the radial movement of the pin star 876, while the limiting portion 960 contacts the roller 918 disposed on the pin 906 that forms the axis T 1, and the rollers 918 disposed on the pins 906 that define the axes T 2 and T 3 contact their respective pin bosses 904, and the rollers 918 disposed on the pin 906 that form the axes T 2 and T 3, The movement along axes T2 and T3 is limited due to the interaction between the arcuate surfaces of rollers 918 and tracks 888.When a propeller shaft, such as the propeller shaft 40, is mounted to a joint 850, manipulation of the propeller shaft when not fully installed in the drive train 20 does not result in damage to the bellows 934 by the bellows bushing 932.While it is shown in FIG. 6 that the shaft 74 may be angled relative to the tulip 70 until the sleeve outer surface 156 of the crimped end 150 of the bellows sleeve 132 contacts the sleeve outer surface 146 of the bellows 134, if restraining portions, such as restraining portions 360, 560, 760, 762, and / or 960, are used to restrain articulation of the joints, contact or damage to a bellows is not present. That is, the limited articulation of the joints need not be directed to the example applications herein.The sections 360, 560, 760, 960 allow a desired amount of articulation of the joint when installed, while preventing undesired angles of articulation leading to damage to the bellows. In the illustrated embodiments, the confining portions 360, 560, 760, 762 are made of a metal alloy, but other materials, for example, hard polyethylene (HDPE), may be used. While the restraining portions 360, 560, 760, 762 are illustrated and described herein as being attached to a shaft, the restraining devices may rotate axially relative to the shaft, move axially relative to the shaft, or otherwise move relative to the shaft. Further, although illustrated as having various shapes, such as cylindrical, curved, and spherical, the outer surfaces of the rollers 118, 318, 518, 718, 918 may have any suitable shape and may limit the radial movement of the spiders 76, 276, 476, 676, 876 as described herein to cooperate with the limiters described herein.As used herein, the articulation of a joint includes non-axial rotation of a portion of the joint relative to another portion of the joint. Generally, this involves non-axial rotation, as can be seen, for example, in comparison to Figures 12 to 13.The foregoing description has been made for purposes of illustrating and describing exemplary embodiments of the methods and systems of the present invention only. It is not intended to be exhaustive or to limit the invention to any specific form disclosed, and it will be understood by those skilled in the art that various changes may be made or equivalents may be substituted for elements without departing from the scope of the invention. Further, many improvements may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. It is therefore intended that the invention not be limited to the specific embodiment disclosed as the best mode for carrying out this invention, but that the invention encompasses all embodiments falling within the scope of the claims. The invention may be practiced otherwise than as specifically explained and illustrated without departing from the spirit or scope of the invention. The scope of the invention is limited only by the following claims.

Claims

A constant velocity universal joint comprising an outer joint portion (270, 470, 670, 870) having an open end (294, 494, 694, 894), an outer joint axis and an outer joint inner surface at least partially defining an inner chamber, an inner joint portion (272, 472, 672, 872) comprising a pin star (276, 476, 676, 876) disposed in the outer joint portion (270, 470, 670, 870), and a shaft (274, 474, 674, 874) extending through the open end (294, 494, 694, 894), wherein the pin star (276, 476, 676, 876) comprises a pin (306, 506, 706, 906) at least partially disposed in the chamber and the shaft (274, 474, 674, 874) defines a shaft axis, Wherein the inner joint portion (272, 472, 672, 872) comprises an angular movement limiting device that limits the angular displacement of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870) to prevent the shaft (274, 474, 674, 874) from contacting the outer joint (270, 470, 670, 870), and a bellows assembly (370, 570, 770, 970) comprising a bellows sleeve (332, 532, 732, 932) and a bellows (334, 534, 734, 934), wherein the bellows sleeve (332, 532, 732, 932) comprises a tulip end (352, 552, 752, 952) connected to the outer joint portion (270, 470, 670, 870) and a crimped end (350, 550, 750, 950) connected to the bellows (334, 534, 734, 934), the bellows (334, 534, 734, 934) having a bellows outer surface (346, 546, 746, 946) and a shaft end (342, 542, 742, 942) connected to the shaft (274, 474, 674, 874), and wherein the angling of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870) results in the restrictor contacting the outer joint portion (270, 470, 670, 870), thereby preventing contact between the bellows outer surface (346, 546, 746, 946) and a bellows sleeve outer surface (356, 556, 756, 956).The constant velocity universal joint of claim 1, wherein the restraining device prevents the shaft (274, 474, 674, 874) from contacting the outer joint inner surface.The constant velocity universal joint of claim 1, wherein the constraining device is a pin crown (308, 508, 708, 908) that selectively contacts the inner surface of the outer joint portion (270, 470, 670, 870).The constant velocity universal joint of claim 1, wherein the restraining device cooperates with the outer joint portion (270, 470, 670, 870) such that the boot (334, 534, 734, 934) does not bindingly engage between the boot liner (332, 532, 732, 932) and the shaft (274, 474, 674, 874).The constant velocity universal joint of claim 1, wherein the limiting device is attached to the shaft (274, 474, 674, 874).The constant velocity universal joint of claim 5, wherein the limiting device comprises a plurality of cams (610), at least one cam (610) selectively contacting a surface of the chamber, thereby allowing the limiting device to limit the deflection of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870).A articulating joint comprising a tulip (270, 470, 670, 870) having an open end (294, 494, 694, 894), a tulip axis, and an inner tulip surface at least partially defining an inner chamber, and an inner joint portion (272, 472, 672, 872) comprising a pin star (276, 476, 676, 876) inserted into the tulip (270, 470, 670, 870), and a shaft (274, 474, 674, 874) extending from the pin star (276, 476, 676, 876) through the open end (294, 494, 694, 894), wherein the pin star (276, 476, 676, 876) comprises a pin (306, 506, 706, 906) at least partially disposed within the chamber, and wherein the shaft (274, 506, 706, 906), A boot seal assembly (370, 570, 770, 970) comprising a boot liner (332, 532, 732, 932) and a boot (334, 534, 734, 934) wherein the boot liner (332, 532, 732, 932) includes a first cover end (352, 552, 752, 952) connected to the boot (270, 470, 670, 870), forming a shaft axis, wherein the inner joint portion (272, 472, 672, 872) comprises a limiting device that limits the deflection of the shaft (274, 474, 674, 874) relative to the boot (270, 470, 670, 870), and a second cover end (350, 550, 750, 950) connected to the bellows (334, 534, 734, 934), and wherein the bellows (334, 534, 734, 934) has a bellows outer surface (346, 546, 746, 946) and a shaft end (342, 542, 742, 942) connected to the shaft (274, 474, 674, 874), and wherein the selective angling of the shaft (274, 474, 674, 874) relative to the tulip (270, 470, 670, 870) results in the restriction device interacting with the tulip (270, 470, 670, 870) such that the bellows (334, 534, 734, 934) does not bind between the bellows sleeve (332, 532, 732, 932) and the shaft (274, 474, 674, 874).The joint of claim 7, wherein the restraining device prevents the shaft (274, 474, 674, 874) from contacting the tulip inner surface.The joint of claim 7, wherein the constraining device is a pin crown (308, 508, 708, 908) that contacts the tulip inner surface.The joint of claim 7, wherein the restriction device prevents contact between a bladder outer surface (346, 546, 746, 946) and a bladder liner outer surface (356, 556, 756, 956).The joint of claim 7, wherein the restriction device comprises a cam and wherein the selective contact between the cam (610) and a surface of the chamber prevents a portion of the bladder sleeve (332, 532, 732, 932) from contacting a portion of the bladder (334, 534, 734, 934).The joint of claim 7, wherein the tulip (270, 470, 670, 870) has three chambers (286, 486, 686, 886) and the pin star (276, 476, 676, 876) has a generally cylindrical pin (306, 506, 706, 906) extending into each chamber (286, 486, 686, 886), and wherein each pin (306, 506, 706, 906) is surrounded by a roller unit (310, 510, 710, 910) contacting a surface portion of at least one of the three chambers (286, 486, 686, 886).The joint of claim 7, wherein the tulip inner surface comprises a first inner surface (290, 490, 690, 890) and a second inner surface (292, 492, 692, 892), wherein the first inner surface (290, 490, 690, 890) generally forms a first chamber diameter (Dv), and the second inner surface (292, 492, 692, 892) generally forms a second chamber diameter (dv), and wherein the chamber major diameter is greater than the chamber minor diameter and wherein the restriction device contacts the first inner surface (290, 490, 690, 890) or the second inner surface (292, 492, 692, 892).A drive shaft comprising an angularly movable joint connecting a first joint shaft (52) to a second joint shaft (54), the joint (50) comprising an outer joint portion (270, 470, 670, 870) and an inner joint portion (272, 472, 672, 872), the outer joint portion (270, 470, 670, 870) having an open end (294, 494, 694, 894), an outer joint axis and an inner surface of the outer joint portion (270, 470, 670, 870) forming at least a portion of an inner chamber, and the inner joint portion (272, 472, 672, 872) comprising a spider (276, 476, 676, 876) inserted into the outer joint portion (270, 470, 670, 870) and a shaft (274, 474, 674, 874), A bellows assembly (370, 570, 770, 970) extending through the open end (294, 494, 694, 894), wherein the pin star (276, 476, 676, 876) comprises a pin (306, 506, 706, 906), wherein the pin (306, 506, 706, 906) is at least partially disposed in the chamber and wherein the shaft (274, 474, 674, 874) forms a shaft axis, and wherein the inner joint portion (272, 472, 672, 872) comprises an angular range limiting device that selectively limits the angular displacement of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870) to prevent the shaft (274, 474, 674, 874) from contacting the outer joint (270, 470, 670, 870) and a bellows assembly (370, 570, 770, 970), which comprises a bellows sleeve (332, 532, 732, 932) and a bellows (334, 534, 734, 934), wherein the bellows sleeve (332, 532, 732, 932) has a first cover end (352, 552, 752, 952) connected to the outer joint portion (270, 470, 670, 870) and a second cover end (350, 550, 750, 950) connected to the bellows (334, 534, 734, 934), wherein the bellows (334, 534, 734, 934) has a bellows outer surface (346, 546, 746, 946) and a shaft end (342, 542, 742, 942) connected to the shaft (274, 474, 674, 874), and wherein the deflection of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870) results in the constraining device contacting the outer joint portion (270, 470, 670, 870), thereby preventing contact between a bladder outer surface (346, 546, 746, 946) and a bladder liner outer surface (356, 556, 756, 956).The drive shaft of claim 14, wherein the restriction device is a pin crown (308, 508, 708, 908) extending from the pin (306, 506, 706, 906) to a surface of the chamber, and wherein the pin crown (308, 508, 708, 908) selectively contacts a portion of the surface of the chamber to restrict the deflection of the shaft (274, 474, 674, 874) relative to the outer joint portion (270, 470, 670, 870).The drive shaft of claim 14, wherein the limiting device is disposed between the spider (276, 476, 676, 876) and the first propeller shaft (52).The drive shaft of claim 14, wherein the limiting device is disposed between the spider (276, 476, 676, 876) and the second propeller shaft (54).

Images