Cover for a universal joint of a driveshaft

Abstract

Kits for a cover for a universal joint of a driveshaft include at least a first section and a second section of a cover, at least two cover fasteners, and at least one driveshaft fastener. The at least two cover fasteners configured to connect the first section to the second section, and the at least one driveshaft fastener configured to connect the cover to the driveshaft or to a yoke of the driveshaft without any portion of the cover contacting the universal joint. The kits also include a plurality of inserts and / or a plurality of pads configured to allow the cover to adapt to driveshafts of varying diameters without changing the size or shape of the cover itself.

Description

COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTCROSS REFERENCES AND PRIORITIES

[0001] This Application claims priority to United States Application No. 18 / 611,768filed on 21 March 2024, the teachings of which are incorporated by reference herein intheir entirety.BACKGROUND

[0002] Universal joints are used in drive trains of many vehicles to connect driveshafts(or segments thereof) to various other vehicle components such as an engine,transmission, or drive axle. The universal joints are flexible joints that permit the variousvehicle components – including the driveshaft (or segment thereof) – to be positionedout of a straight-line alignment with one another. Universal joints (commonly referred toas “U-Joints”) differ from constant-velocity joints (commonly referred to as “CV Joints”)in that the universal joints typically come in a basic “cross” pattern and do not maintaina constant velocity at varying operational angles.

[0003] Many universal joints require lubrication and have grease fittings to accommodatesuch lubrication. As the drive shaft spins at high speed, the grease / oil in the universaljoint is flung off the universal joint by the centrifugal force of the spinning universal joint.This grease / oil is deposited on portions of the vehicle – most notably the vehicleundercarriage – resulting in the need for repeated cleanings of the vehicle. A portion ofthe grease / oil is also typically deposited onto the road surface upon which the vehicle isdriving which can result in damage to the road surface and / or environmentalcontamination and pollution.

[0004] Several solutions to prevent grease / oil from being flung off the universal joint andonto the vehicle have been proposed. The simplest of which is to dispose a flexible covermade of materials such as rubber or fabric around the portion of the vehicle driveshaftthat includes the universal joint. One such solution is disclosed in United States PatentPublication No.2009 / 0227383 which discloses a flexible, removable universal joint coverincluding a removable, reusable outer flexible shell and a removable, flexible liner.

[0005] In practice the existing solutions suffer from many defects. Most notably, theknown solutions often attach to the driveshaft in a manner such that a portion of thecover comes into direct contact with the universal joint. The spinning universal joint maythen damage the cover during use. This is particularly the case with covers of flexiblematerials such as rubber or fabric which may also be weakened or fatigued by thegrease / oil flung from the universal joint as well as road debris such as rainwater, ice,rocksalt, and the like. Worse yet, the damage caused to the cover may result in full orCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTpartial loss of functionality of the universal joint as the damaged cover material maybecome lodged in the universal joint. In addition, many of the prior art solutions aredesigned as an uninterrupted cylinder which must be installed before connecting thedriveshaft to other components, making repair or replacement of the cover difficult. Thisalso limits or prevents access to the universal joint and its associated grease fitting whichimpedes the ability to service the universal joint.

[0006] The need exists, therefore, for a cover for a driveshaft universal joint which canwithstand the harsh environments associated with the underside of a vehicle and whichcan be easily installed, repaired, and / or replaced.SUMMARY

[0007] Described herein is a kit for a cover for a universal joint of a driveshaft. The kitincludes a first section, a second section, a plurality of inserts, at least two cover fasteners,and at least one driveshaft fastener.

[0008] The first section has a first section first end, a first section second end oppositethe first section first end, a first section first edge extending between a first section firstend first end-point and a first section second end first end-point, a first section secondedge extending between a first section first end second end-point and a first sectionsecond end second end-point, a first longitudinal axis, and a first radius.

[0009] The second section has a second section first end, a second section second endopposite the second section first end, a second section first edge extending between asecond section first end first end-point and a second section second end first end-point,a second section second edge extending between a second section first end second end-point and a second section second end second end-point, a second longitudinal axis, anda second radius.

[0010] Each insert of the plurality of inserts has an insert sidewall having an inner surfaceand an outer surface, a third longitudinal axis, an inner diameter, and at least one sidewalllongitudinal gap. Each insert of the plurality of inserts has a different inner diameter.

[0011] At least a first cover fastener of the at least two cover fasteners is configured toconnect the first section first edge to the second section first edge; at least a second coverfastener of the at least two cover fasteners is configured to connect the first section secondedge to the second section second edge. The at least one driveshaft fastener is configuredto connect the cover to the driveshaft or to a yoke of the driveshaft without any portionof the cover contacting the universal joint.COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFT

[0012] In some embodiments, each insert of the plurality of inserts includes at least oneinward protrusion extending from the inner surface of the insert sidewall.

[0013] In certain embodiments, the first section first edge may include a first groove. Insuch embodiments, the first section second edge may include a second groove. Further,in such embodiments, the second section first edge may include a third groove. Also, insuch embodiments, the second section second edge may include a fourth groove. Eachinsert of the plurality of inserts may include at least a first outward protrusion extendingfrom the outer surface of the insert sidewall, and a second outward protrusion extendingfrom the outer surface of the insert sidewall. The first outward protrusion may beconfigured to nest between the first groove and the third groove when the first section isconnected to the second section, and the second outward protrusion may be configuredto nest between the second groove and the fourth groove when the first section isconnected to the second section.

[0014] In some embodiments, the first section first edge may include a first section firstflange, the second section first edge may include a second section first flange (125), andthe first cover fastener may be configured to connect the first section first edge to thesecond section first edge by passing through the first section first flange and into thesecond section first flange or by passing through the second section first flange and intothe first section first flange.

[0015] In certain embodiments, the first section second edge may include a first sectionsecond flange, the second section second edge may include a second section secondflange, and the second cover fastener may be configured to connect the first sectionsecond edge to the second section second edge by passing through the first section secondflange and into the second section second flange or by passing through the second sectionsecond flange and into the first section second flange.

[0016] In some embodiments, the first section may include a first step-down extendingfrom a first position along a first length of the first section to the first section second end,and the second section may include a second step-down extending from a second positionalong a second length of the second section to the second section second end. In certainsuch embodiments, each insert of the plurality of inserts may be configured to nestbetween at least a portion of the first step-down and at least a portion of the second step-down.

[0017] In certain embodiments, when the at least one driveshaft fastener is configuredto connect the cover to the yoke of the driveshaft, the first section second end may includeCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTat least one first radial flange, the second section second end may include at least onesecond radial flange, the at least one driveshaft fastener may include at least a first U-boltand a second U-bolt (142), the first U-bolt may be configured to connect the at least onefirst radial flange to the yoke, and the second U-bolt may be configured to connect the atleast one second radial flange to the yoke.

[0018] In some embodiments, the first section, the second section, and each insert of theplurality of inserts may each independently be composed of a semi-rigid polymericmaterial. In certain such embodiments, the semi-rigid polymeric material may bepolypropylene, high density polyethylene, or nylon.

[0019] In other embodiments, the first section, the second section, and each insert of theplurality of inserts may each independently be composed of a metal material selected fromthe group consisting of steel and aluminum.

[0020] In some embodiments, each cover fastener of the at least two cover fasteners maybe a self-tapping screw, a socket head cap screw, or a threaded insert.

[0021] Also disclosed herein is a kit for a cover for a universal joint of a driveshaft. Thekit includes a first section, a second section, a plurality of pads, at least two cover fasteners,and at least one driveshaft fastener.

[0022] The first section has a first section first end, a first section second end oppositethe first section first end, a first section first edge extending between a first section firstend first end-point and a first section second end first end-point, a first section secondedge extending between a first section first end second end-point and a first sectionsecond end second end-point, a first longitudinal axis, and a first radius.

[0023] The second section has a second section first end, a second section second endopposite the second section first end, a second section first edge extending between asecond section first end first end-point and a second section second end first end-point,a second section second edge extending between a second section first end second end-point and a second section second end second end-point, a second longitudinal axis, anda second radius.

[0024] Each pad of the plurality of pads includes a pad sidewall having a pad inner surfaceand a pad outer surface, a pad attachment member located in the pad outer surface, andan inner arch diameter. At least two pads of the plurality of pads have a different innerarch diameter. The pad attachment member of each pad of the plurality of pads isconfigured to connect to a first attachment member of the at least one first attachmentCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTmember and / or a second attachment member of the at least one second attachmentmember.

[0025] At least a first cover fastener of the at least two cover fasteners is configured toconnect the first section first edge to the second section first edge; at least a second coverfastener of the at least two cover fasteners is configured to connect the first section secondedge to the second section second edge. The at least one driveshaft fastener is configuredto connect the cover to the driveshaft or to a yoke of the driveshaft without any portionof the cover contacting the universal joint.

[0026] In some embodiments, the first section first edge may include a first section firstflange, the second section first edge may include a second section first flange (125), andthe first cover fastener may be configured to connect the first section first edge to thesecond section first edge by passing through the first section first flange and into thesecond section first flange or by passing through the second section first flange and intothe first section first flange.

[0027] In certain embodiments, the first section second edge may include a first sectionsecond flange, the second section second edge may include a second section secondflange, and the second cover fastener may be configured to connect the first sectionsecond edge to the second section second edge by passing through the first section secondflange and into the second section second flange or by passing through the second sectionsecond flange and into the first section second flange.

[0028] In some embodiments, the first section may include a first step-down extendingfrom a first position along a first length of the first section to the first section second end,and the second section may include a second step-down extending from a second positionalong a second length of the second section to the second section second end. In certainsuch embodiments, each insert of the plurality of inserts may be configured to nestbetween at least a portion of the first step-down and at least a portion of the second step-down.

[0029] In certain embodiments, when the at least one driveshaft fastener is configuredto connect the cover to the yoke of the driveshaft, the first section second end may includeat least one first radial flange, the second section second end may include at least onesecond radial flange, the at least one driveshaft fastener may include at least a first U-boltand a second U-bolt (142), the first U-bolt may be configured to connect the at least onefirst radial flange to the yoke, and the second U-bolt may be configured to connect the atleast one second radial flange to the yoke.COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFT

[0030] In some embodiments, the first section, the second section, and each pad of theplurality of pads may each independently be composed of a semi-rigid polymeric material.BRIEF DESCRIPTION OF FIGURES

[0031] FIG. 1 is an exploded perspective view of one embodiment of a cover for auniversal joint of a driveshaft.

[0032] FIG. 2 is an assembled perspective view of the embodiment of a cover of FIG. 1.

[0033] FIG. 3 is an exploded perspective view of one embodiment of a cover for auniversal joint of a driveshaft.

[0034] FIG. 4 is an assembled perspective view of the embodiment of a cover of FIG. 3.

[0035] FIG.5 is a longitudinal cross-sectional view of the embodiment of a cover of FIGS.3 and 4 connected to a driveshaft.

[0036] FIG. 6 is an exploded perspective view of one embodiment of a cover for auniversal joint of a driveshaft.

[0037] FIG. 7 is a longitudinal cross-sectional view of the embodiment of a cover of FIG.4 connected to a yoke of a driveshaft.

[0038] FIG. 8 is an interior view of two sections of an embodiment of a cover for auniversal joint of a driveshaft.

[0039] FIG. 9 is a longitudinal cross-sectional view of the embodiment of a cover of FIG.8 connected to a driveshaft having a double cardan universal joint.

[0040] FIG. 10 is an interior view of three sections of an embodiment of a cover for auniversal joint of a driveshaft.

[0041] FIG. 11 is a perspective view of an insert for a cover for a universal joint of adriveshaft.

[0042] FIG. 12 is an exploded side view of an insert with a portion of a cover for auniversal joint of a driveshaft.

[0043] FIG. 13 is an assembled view of FIG. 12.

[0044] FIG. 14 is an axial cross-section view of a cover for a universal joint of a driveshaftwith an insert connected to a driveshaft.

[0045] FIG. 15 is a perspective view of an embodiment of a cover kit for a universal jointof a driveshaft.

[0046] FIG. 16 is a perspective view of a pad for a cover for a universal joint of adriveshaft.

[0047] FIG. 17 is an exploded perspective view of a pad with a portion of a cover for auniversal joint of a driveshaft.COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFT

[0048] FIG. 18 is an assembled view of FIG. 17.

[0049] FIG. 19 is a radial cross-section view of a cover for a universal joint of a driveshaftwith a pad connected to a driveshaft.

[0050] FIG. 20 is a perspective view of an embodiment of a cover kit for a universal jointof a driveshaft.DETAILED DESCRIPTION

[0051] Disclosed herein is a cover for a universal joint of a driveshaft. The cover isdescribed below with reference to the Figures. As described herein and in the claims, thefollowing numbers refer to the following structures as noted in the Figures.

[0052] 5 refers to a driveshaft.

[0053] 10 refers to a universal joint.

[0054] 12 refers to a double cardan universal joint.

[0055] 20 refers to a yoke.

[0056] 22 refers to a yoke of a double cardan universal joint.

[0057] 100 revers to a cover.

[0058] 110 refers to a first section.

[0059] 111 refers to a first section first end.

[0060] 112 refers to a first section second end.

[0061] 113 refers to a first section first edge.

[0062] 114 refers to a first section second edge.

[0063] 115 refers to a first section first flange.

[0064] 116 refers to a first section second flange.

[0065] 117 refers to a first step-down.

[0066] 118 refers to a first radial flange.

[0067] 119 refers to a pair of first tabs.

[0068] 120 refers to a second section.

[0069] 121 refers to a second section first end.

[0070] 122 refers to a second section second end.

[0071] 123 refers to a second section first edge.

[0072] 124 refers to a second section second edge.

[0073] 125 refers to a second section first flange.

[0074] 126 refers to a second section second flange.

[0075] 127 refers to a second step-down.

[0076] 128 refers to a second radial flange.COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFT

[0077] 129 refers to a pair of second tabs.

[0078] 130 refers to a cover fastener.

[0079] 140 refers to a driveshaft fastener.

[0080] 141 refers to a first U-bolt.

[0081] 142 refers to a second U-bolt.

[0082] 150 refers to a third section.

[0083] 171 refers to a first groove.

[0084] 172 refers to a second groove.

[0085] 173 refers to a third groove.

[0086] 174 refers to a fourth groove.

[0087] 200 refers to an insert.

[0088] 210 refers to an insert sidewall.

[0089] 211 refers to an inner surface (of an insert sidewall).

[0090] 212 refers to an outer surface (of an insert sidewall).

[0091] 213 refers to a sidewall longitudinal gap.

[0092] 220 refers to an inward protrusion.

[0093] 231 refers to a first outward protrusion.

[0094] 232 refers to a second outward protrusion.

[0095] 300 refers to a pad.

[0096] 310 refers to a pad sidewall.

[0097] 311 refers to a pad inner surface.

[0098] 312 refers to a pad outer surface.

[0099] 320 refers to a pad attachment member.

[0100] 410 refers to a first attachment member.

[0101] 420 refers to a second attachment member.

[0102] α1 refers to a first longitudinal axis.

[0103] r1 refers to a first radius.

[0104] α2 refers to a second longitudinal axis.

[0105] r2 refers to a second radius.

[0106] α3 refers to a third longitudinal axis.

[0107] d1 refers to an inner diameter.

[0108] d2 refers to an inner arch diameter.

[0109] FIG. 1 and FIG. 2 show one embodiment of a cover (100) for a universal joint(10 as shown in FIG. 5) of a driveshaft (5 as shown in FIG. 5) with FIG. 1 being anCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTexploded perspective view and FIG. 2 being an assembled perspective view. As shown inFIG. 1 and FIG. 2, the cover is divided into at least two sections referred to herein as afirst section (110) and a second section (120). When assembled, the first section and thesecond section (and optional further sections) form the cover which has a substantiallycylindrical profile as shown in FIG. 2. As the assembled cover has a substantiallycylindrical profile, each of the sections (including at least the first section and the secondsection) have a substantially semi-cylindrical profile as shown in FIG. 1.

[0110] FIG. 1 shows the first section (110) having a first section first end (111) and a firstsection second end (112) opposite the first section first end. A first section first edge (113)extends between first end-points of the first section first end and the first section secondend. Similarly, a first section second edge (114) extends between second end-points of thefirst section first end and the first section second end. As the first section has asubstantially semi-cylindrical profile, the first section will have a first longitudinal axis (α1)and a first radius (r1) as shown in FIG. 1. Further, the substantially semi-cylindrical profileof the first section provides for the first section first end and the first section second endforming an arch in a range of between about 30° and about 330°, preferably in a range ofbetween about 90° and about 270°, and more preferably in a range of between about 135°and 225°. In the embodiment shown in FIG. 1 the first section first end and the firstsection second end form an arch of about 180°.

[0111] The second section (120) may be similar in construction to the first section (110)as shown in FIG. 1. That is to say that the second section has a second section first end(121) and a second section second end (122) opposite the second section first end. Asecond section first edge (123) extends between first end-points of the second section firstend and the second section second end. Similarly, a second section second edge (124)extends between second end-points of the second section first end and the second sectionsecond end. As the second section has a substantially semi-cylindrical profile, the secondsection will have a second longitudinal axis (α2) and a second radius (r2) as shown in FIG.1. Further, the substantially semi-cylindrical profile of the second section provides for thesecond section first end and the second section second end forming an arch in a range ofbetween about 30° and about 330°, preferably in a range of between about 90° and about270°, and more preferably in a range of between about 135° and 225°. In the embodimentshown in FIG. 1 the second section first end and the second section second end form anarch of about 180°.COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFT

[0112] While the Figures show a cover (100) comprising two sections, embodiments mayexist having more than two sections. Each additional section – when present – may haveits own independent additional section first end and additional section second endopposite the additional section first end. Each additional section – when present – mayalso have its own independent additional section first edge extending between first end-points of the additional section first end and the additional section second end, andadditional section second edge extending between second end-points of the additionalsection first end and the additional section second end. As each additional section has asubstantially semi-cylindrical profile, each additional section will have an additionalsection longitudinal axis and an additional section first radius. Further, the substantiallysemi-cylindrical profile of each additional section provides for each additional section firstend and each additional section second end forming an arch in a range of between about30° and about 300°, preferably in a range of between about 90° and about 240°, and morepreferably in a range of between about 135° and 195°.

[0113] Regardless of the number of sections, the sum of the arches of all the section’sfirst ends will equal 360°. Similarly, the sum of the arches of all the section’s second endswill also equal 360°. As such, the sections may be attached to one another in such a wayas to form a single cover (100) having a substantially cylindrical profile.

[0114] FIG. 1 also shows the cover comprising cover fasteners (130). At least a first coverfastener will be configured to connect the first section first edge (113) to the secondsection first edge (123). Similarly, at least a second cover fastener will be configured toconnect the first section second edge (114) to the second section second edge (124). Thepreferred cover fastener is a self-tapping screw, a socket head cap screw, or a threadedinsert. Alternatively, other types of cover fastener may be utilized including screws, bolts(with or without nuts), rivets, clips, clamps, and the like.

[0115] Further shown in FIG. 2 is at least one driveshaft fastener (140). The at least onedriveshaft fastener will be configured to connect the cover (100) to the driveshaft (5 asshown in FIG. 5) and / or a yoke (20 as shown in FIG. 5) of the driveshaft. Examples of adriveshaft fastener include clamps (such as worm gear clamps, spring clamps, wire clamps,ear clamps, and the like), screws, bolts, rivets, and the like. When connected to thedriveshaft or yoke, no portion of the cover contacts the universal joint (10 as shown inFIG. 5).

[0116] FIG. 1 further shows the first section first edge (113) comprising a first sectionfirst flange (115), and the second section first edge (123) comprising a second section firstCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTflange (125). The first section first flange is located along at least a portion – and in someembodiments all – of the first section first edge and is aligned substantially parallel withthe first longitudinal axis (α1). Similarly, the second section first flange is located along atleast a portion – and in some embodiments all – of the second section first edge and isaligned substantially parallel with the second longitudinal axis (α2). Each of the firstsection first flange and the second section first flange are considered optional featuresand may not be present in certain embodiments. When the flanges are present, the atleast one first cover fastener is configured to connect the first section first edge to thesecond section first edge by passing through the first section first flange and into thesecond section first flange – or by passing through the second section first flange and intothe first section first flange. As such, one or both of the first section first flange and / orthe second section first flange may comprise a hole passing through the respective flangethrough which the at least one first cover fastener may pass.

[0117] FIG. 1 further shows the first section second edge (114) comprising a first sectionsecond flange (116), and the second section second edge (124) comprising a secondsection second flange (126). The first section second flange is located along at least aportion – and in some embodiments all – of the first section second edge and is alignedsubstantially parallel with the first longitudinal axis (α1). Similarly, the second sectionsecond flange is located along at least a portion – and in some embodiments all – of thesecond section second edge and is aligned substantially parallel with the secondlongitudinal axis (α2). Each of the first section second flange and the second sectionsecond flange are considered optional features and may not be present in certainembodiments. When the flanges are present, the at least one second cover fastener isconfigured to connect the first section second edge to the second section second edge bypassing through the first section second flange and into the second section second flange– or by passing through the second section first flange and into the first section secondflange. As such, one or both of the first section second flange and / or the second sectionfirst flange may comprise a hole passing through the respective flange through which theat least one second cover fastener may pass.

[0118] FIG.3 through FIG.5 show embodiments of the cover (100) which include a step-down portion. As shown in FIG. 3, which is an exploded perspective view of anembodiment which includes a step-down portion, the first section (110) comprises a firststep-down (117) extending from a first position along a first length of the first section toCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTthe first section second end (112). This first step-down may be considered as a third radiusof the first section which is less than the first radius (r1).

[0119] Similarly, the second section (120) may comprise a second step-down (127)extending from a second position along a second length of the second section to thesecond section second end (122) as shown in FIG. 3. This second step-down may beconsidered as a fourth radius of the second section which is less than the second radius(r2). Preferably the fourth radius of the second section will be substantially similar oridentical in dimension to the third radius of the first section.

[0120] In embodiments where the cover (100) comprises additional sections, eachadditional section may also include a step-down. When present, the step-down in eachadditional section will extend from a position along a length of the additional section tothe additional section’s second end. The additional section step-down may be consideredas an additional section second radius which is less than the additional section radius.Preferably each additional section second radius will be substantially similar or identicalin dimension to one (preferably both) of the third radius of the first section and / or thefourth radius of the second section.

[0121] When assembled – as shown in FIG. 4 – the sections, including their step-downs,form the cover (100) with the cover having a first cover radius proximate to the first end,and a second cover radius proximate to the second end with the dimension of the secondcover radius being less than that of the first cover radius.

[0122] FIG. 5 shows a longitudinal cross-section view of an embodiment of the cover(100) with a step-down portion connected to a driveshaft (5) or a slip joint of a driveshaftwhich includes a universal joint (10) and a yoke (20). While the embodiment in FIG. 5 islabelled with numbering corresponding to the first section (110), the structure andconfiguration applies equally to the second section.

[0123] As shown in FIG. 5, a portion of cover (100) which is in the step-down area maybe configured to contact the driveshaft (5) when the at least one driveshaft fastener (140)connects the cover to the driveshaft. No portion of the cover contacts the universal jointas shown in FIG. 5.

[0124] FIG. 6 and FIG. 7 show embodiments of the cover (100) comprising radial flangesfor connecting to yoke U-bolts. As shown in FIG. 6, which is an exploded perspectiveview of an embodiment which includes radial flanges, the first section second end (112as shown in FIG. 1) comprises at least one first radial flange (118). In preferredembodiments, the first section second end will comprise two first radial flanges as shownCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTin FIG. 6 and FIG. 7. The first radial flange(s) may extend inwardly from the first sectionsecond end along all or a portion of the arch of the first section second end. One or morefirst radial flange hole(s) which are configured in size, shape, and location to receive a firstU-bolt (141) which connects the yoke (20) to the universal joint (10) may pass througheach first radial flange.

[0125] Similarly, the second section second end (122 as shown in FIG. 1) comprises atleast one second radial flange (128) as shown in the embodiment shown in FIG. 6. Inpreferred embodiments, the second section second end will comprise two second radialflanges as shown in FIG. 6 and FIG. 7. The second radial flange(s) may extend inwardlyfrom the second section second end along all or a portion of the arch of the secondsection second end. One or more second radial flange hole(s) which are configured insize, shape, and location to receive a second U-bolt (142) which connects the yoke (20) tothe universal joint (10) may pass through each second radial flange.

[0126] The embodiment shown in FIG. 6 and FIG. 7 also shows an alternativeembodiment for connecting the first section (110) to the second section (120). In thisembodiment, a tongue and groove connection connects the first section to the secondsection. A tongue being disposed on at least one end-point of one of either the first sectionor the second section. The opposing end-point on the other section having a grooveconfigured to securely receive the tongue. For instance, when the second end-point of thesecond section comprises a tongue (as shown in FIG. 6), the second end-point of the firstsection will comprise a groove configured to securely receive the tongue.

[0127] In embodiments where the cover (100) comprises additional sections, one or moreof the additional section(s) may comprise at least one additional section radial flange.Each additional section radial flange may extend inwardly from the additional sectionsecond end along all or a portion of the arch of the additional section second end. Oneor more additional section radial flange hole(s) which are configured in size shape, andlocation to receive a U-bolt which connects the yoke (20) to the universal joint (10) maypass through each additional section radial flange. One or more of the additionalsection(s) may also include a tongue and groove connection for connecting the additionalsection(s) to one another and / or to the first section (110) and / or the second section(120).

[0128] FIG. 7 shows a longitudinal cross-section view of an embodiment of the cover(100) that includes radial flanges for connecting to driveshaft U-bolts. While theCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTembodiment in FIG.7 is labelled with numbering corresponding to the first section (110),the structure and configuration applies equally to the second section.

[0129] As shown in FIG. 7, the at least one driveshaft fastener comprises at least a firstU-bolt (141) and a second U-bolt (142 as shown in FIG. 6). These driveshaft fasteners areconfigured to connect the cover (100) to the yoke (20) of the driveshaft (5). The first U-bolt is configured to connect the first section (110) to the yoke by passing the first U-boltthrough hole(s) in the first radial flange (118). The second U-bolt is configured to connectthe second section (120) to the yoke by passing the second U-bolt through hole(s) in thesecond radial flange (128). As the radial flanges of the cover contact the yoke, no portionof the cover contacts the universal joint as shown in FIG. 7.

[0130] FIGS. 8 and 9 show an alternative embodiment of a cover (100) which isspecifically adapted for use with a double cardan universal joint (12 as shown in FIG. 9).FIG. 8 is an exploded and partially unwrapped view of the cover. As shown in FIG. 8, thefirst section (110) may comprise a pair of first tabs (119). Each first tab of the pair of firsttabs extends inwardly from an interior wall of the first section.

[0131] Similarly, FIG. 8 shows the second section (120) which may comprise a pair ofsecond tabs (129). Each second tab of the pair of second tabs extends inwardly from aninterior wall of the second section. Each of the pair of first tabs and the pair of secondtabs is configured to engage a yoke of a double cardan universal joint (22) as shown inFIG. 9.

[0132] In embodiments where the cover (100) comprises additional sections (150), asshown in FIG. 10, one or more of the additional section(s) may comprise a pair ofadditional section tabs. Each pair of additional section tabs may extend inwardly from aninterior wall of the additional section. Each pair of additional tabs may be configured toengage a yoke of a double cardan universal joint (22).

[0133] FIG. 11 illustrates an insert (200) which may be used with any of the coversdisclosed herein to allow the cover to adapt to driveshafts of varying diameters withoutchanging the size or shape of the cover itself. In some embodiments, the cover may be inthe form of a kit (an embodiment of which is shown in FIG. 15) comprising at least a firstcover section (110) and a second cover section (120), at least two cover fasteners (130), atleast one driveshaft fastener (140), and a plurality of inserts. Preferably, each insert of theplurality of inserts in the kit will have a different inner diameter (d1).

[0134] Each insert (200) – when present – has an insert sidewall (210) having an innersurface (211) and an outer surface (212). Preferably, the insert will have a substantiallyCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTcylindrical profile as shown in FIG. 11 with a third longitudinal axis (α3) and an innerdiameter (d1). Preferably at least one sidewall longitudinal gap (213) will pass through theinsert sidewall from the outer surface through the inner surface spanning the entire lengthof the insert sidewall and allowing the insert to be placed around at least a portion of auniversal joint and a driveshaft without having to remove the driveshaft assembly.

[0135] In some embodiments, the insert (200) may further include one or more surfacefeatures at the inner surface of the insert sidewall configured to adapt to a portion of thedriveshaft and / or the yoke as shown in FIG. 14. One such surface feature is shown inFIG. 11 which illustrates an inward protrusion (220). Nonlimiting examples of othersurface features include indentation(s), groove(s), blind hole(s), slot(s), and the like.

[0136] FIG. 12 and FIG. 13 illustrate exploded side (FIG. 12) and assembled side (FIG.13) views of a cover section (which may be the first section (110) or the second section(120)) and an insert (200). As shown in FIG. 12 and FIG. 13, in some embodiments, thefirst section first edge (113) may include a first groove (171), the first section second edge(114) may include a second groove (172), the second section first edge (123) may includea third groove (173), and the second section second edge (124) may include a fourthgroove (174). In such embodiments, the insert(s) may include at least a first outwardprotrusion (231) and a second outward protrusion (232) with the first outward protrusionextending from the outer surface (212) of the insert sidewall (210) and the second outwardprotrusion extending from a second position on the outer surface of the insert sidewallas shown in FIG. 12. When the cover is assembled, the first outward protrusion isconfigured to nest between the first groove and the third groove while the second outwardprotrusion is configured to nest between the second groove and the fourth groove.

[0137] FIG. 16 illustrates a pad (300). A plurality of pads may be used with any of thecovers disclosed herein – including those illustrated in FIGS.17 to 20 – to allow the coverto adapt to driveshafts of varying diameters without changing the size or shape of thecover itself. In some embodiments, the cover may be in the form of a kit (an embodimentof which is shown in FIG. 20) comprising at least a first cover section (110) and a secondcover section (120), at least two cover fasteners (130), at least one driveshaft fastener (140),and a plurality of pads. Preferably, at least two pads of the plurality of pads have a differentinner arch diameter (d2).

[0138] Each pad (300) – when present – has a pad sidewall (310) having a pad innersurface (311) and a pad outer surface (312). When viewed from an end thereof, each padCOVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTwill have an arched profile with an inner arch diameter formed by extending the innerarch 360 degrees to form a circle.

[0139] At or within a portion of the pad outer surface (312) may be a pad attachmentmember (320). The pad attachment member may take many different forms, anexemplary embodiment of which is shown in FIGS. 16 to 19. In the exemplaryembodiment, the pad attachment member is in the form of a groove disposed in the padouter surface beginning at one circumferential edge of the pad. The groove may have anumber of different profiles with the Figures illustrating a “T” profile configured tointeract with a “T” shaped attachment member (410 / 420 as illustrated in FIGS. 17 to 19)of one or both of the first section and / or the second section. While the groove may extendfrom the first circumferential edge of the pad through the second circumferential edge ofthe pad, it is preferred that the groove originate at one circumferential edge of the padwithout extending through the opposing circumferential edge of the pad as shown in theFigures.

[0140] FIG. 17 and FIG. 18 illustrate the connection of a pad (300) to a cover section(which may be the first section (110) or the second section (120)) with FIG. 17 showingthe pad and cover section separate (exploded) and FIG. 18 showing the pad and coversection connected to one another. As shown in FIG. 17, the pad attachment member(320) is first aligned with the attachment member (410 / 420) of the correspondingsection. The pad attachment member is then engaged to the attachment member. In theexemplary embodiment shown in FIG. 17 and FIG. 18, the engagement of the padattachment member to the attachment member occurs by sliding the pad attachmentmember – which is a groove having a “T” shaped profile – over and around theattachment member – which is a protrusion from the inner sidewall of the cover sectionalso having a “T” shaped profile. However, other embodiments of engagement membermay exist including grooves and protrusions having different profiles, a groove in theinner sidewall of the cover section and a protrusion extending from the pad outer surface(312), snaps, and fasteners such as rivets, screws, bolts and the like.

[0141] FIG. 19 illustrates a cover (100) comprising a first section (110) and a secondsection (120) having a plurality of pads (300) attached thereto connected to a segment ofa driveshaft (5). As shown in FIG. 19, the plurality of pads is first connected to the firstattachment member (410) of the first cover section and the second attachment member(420) of the second cover section respectively. The cover sections – with pads installed –COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTis then disposed around and secured to the section of the driveshaft utilizing the at leasttwo cover fasteners and the at least one driveshaft fastener as described herein.

[0142] One or more of the sections of the cover – including the first section, the secondsection, the optional additional section(s), the plurality of inserts, and the plurality ofpads – may be fabricated of a material. Preferably, the material of each of the sections isa semi-rigid polymeric material with the preferred semi-rigid polymeric material beingpolypropylene, high density polyethylene, or nylon. By semi-rigid it is meant that thematerial has a modulus of elasticity greater than 1.90 GPa. Such semi-rigid polymericmaterials may be formed into the various sections using various manufacturingtechniques known in the art and those yet to be developed. One such example of amanufacturing technique is injection molding.

[0143] Alternatively, one or more of the sections of the cover – including the first section,the second section, the optional additional section(s), the plurality of inserts, and theplurality of pads – may be fabricated of a stamped or otherwise formed metal. Examplesof such metals include sheet steel, cast aluminum, or the like.

[0144] The covers described herein address many of the issues associated with the knownsolutions for preventing grease / oil from being flung off the universal joint and onto thevehicle and / or the adjacent roadway. By attaching the cover directly to the driveshaftand / or yoke with no portion of the cover contacting the universal joint, the disclosedcovers are less prone to becoming damaged by the spinning universal joint. This alsoreduces the likelihood that debris from a damaged cover will become lodged in theuniversal joint resulting in partial or full loss of the universal joint’s functionality. Themulti-piece construction of the covers described herein also allow for the cover to beinstalled while the driveshaft is already connected to other components of the vehicle –such as the engine, transmission, drive axle, or other driveshaft segments – makinginstallation, repair, and replacement easier. The multi-piece construction also allows foreasy access to the universal joint and its associated grease fitting during servicing of theuniversal joint.

[0145] While the invention has been described as having an exemplary design, thepresent invention may be further modified within the spirit and scope of this disclosure.This application is therefore intended to cover any variations, uses, or adaptations of theinvention using its general principles.

Claims

COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTCLAIMSWhat is claimed is:

1. A kit for a cover (100) for a universal joint (10) of a driveshaft (5), said kitcomprising: afirst section (110) having a first section first end (111), a first sectionsecond end (112) opposite the first section first end, a first section firstedge (113) extending between a first section first end first end-point and afirst section second end first end-point, a first section second edge (114)extending between a first section first end second end-point and a firstsection second end second end-point, a first longitudinal axis (α1), and afirst radius (r1);a second section (120) having a second section first end (121), a secondsection second end (122) opposite the second section first end, a secondsection first edge (123) extending between a second section first end firstend-point and a second section second end first end-point, a secondsection second edge (124) extending between a second section first endsecond end-point and a second section second end second end-point, asecond longitudinal axis (α2), and a second radius (r2);a plurality of inserts (200), each insert of the plurality of inserts havingan insert sidewall (210) having an inner surface (211) and an outer surface(212), a third longitudinal axis (α3), an inner diameter (d1), and at leastone sidewall longitudinal gap (213);at least two cover fasteners (130); andat least one driveshaft fastener (140); andwherein each insert of the plurality of inserts has a different inner diameter;at least a first cover fastener of the at least two cover fasteners is configured toconnect the first section first edge to the second section first edge; at least a secondcover fastener of the at least two cover fasteners is configured to connect the firstsection second edge to the second section second edge; andthe at least one driveshaft fastener is configured to connect the cover to thedriveshaft or to a yoke of the driveshaft without any portion of the covercontacting the universal joint.COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFT2. The kit of claim 1, wherein each insert of the plurality of inserts includes at leastone inward protrusion (220) extending from the inner surface of the insertsidewall.

3. The kit of claims 1 or 2, wherein:the first section first edge includes a first groove (171);the first section second edge includes a second groove (172);the second section first edge includes a third groove (173);the second section second edge includes a fourth groove (174); andeach insert of the plurality of inserts includes at least a first outwardprotrusion (231) extending from the outer surface of the insert sidewall,and a second outward protrusion (232) extending from the outer surfaceof the insert sidewall; andwherein the first outward protrusion is configured to nest between the first grooveand the third groove when the first section is connected to the second section,and the second outward protrusion is configured to nest between the secondgroove and the fourth groove when the first section is connected to the secondsection.

4. The kit of any of claims 1 to 3, wherein the first section first edge comprises a firstsection first flange (115), the second section first edge comprises a second sectionfirst flange (125), and the first cover fastener is configured to connect the firstsection first edge to the second section first edge by passing through the firstsection first flange and into the second section first flange or by passing throughthe second section first flange and into the first section first flange.

5. The kit of any of claims 1 to 4, wherein the first section second edge comprises afirst section second flange (116), the second section second edge comprises asecond section second flange (126), and the second cover fastener is configuredto connect the first section second edge to the second section second edge bypassing through the first section second flange and into the second section secondflange or by passing through the second section second flange and into the firstsection second flange.

6. The kit of any of claims 1 to 5, wherein the first section comprises a first step-down (117) extending from a first position along a first length of the first sectionto the first section second end, and the second section comprises a second step-COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTdown (127) extending from a second position along a second length of the secondsection to the second section second end.

7. The kit of any of claims 1 to 6, wherein each insert of the plurality of inserts isconfigured to nest between at least a portion of the first step-down and at least aportion of the second step-down.

8. The kit of any of claims 1 to 7, wherein when the at least one driveshaft fasteneris configured to connect the cover to the yoke of the driveshaft, the first sectionsecond end comprises at least one first radial flange (118), the second sectionsecond end comprises at least one second radial flange (128), the at least onedriveshaft fastener comprises at least a first U-bolt (141) and a second U-bolt(142), the first U-bolt is configured to connect the at least one first radial flangeto the yoke, and the second U-bolt is configured to connect the at least one secondradial flange to the yoke.

9. The kit of any of claims 1 to 8, wherein the first section, the second section, andeach insert of the plurality of inserts are each independently composed of a semi-rigid polymeric material.

10. The kit of claim 9, wherein the semi-rigid polymeric material is polypropylene ornylon.

11. The kit of any of claims 1 to 10, wherein the first section, the second section, andeach insert of the plurality of inserts are each independently composed of a metalmaterial selected from the group consisting of steel and aluminum.

12. The kit of any of claims 1 to 11, wherein each cover fastener of the at least twocover fasteners is a self-tapping screw, a socket head cap screw, or a threaded insert.

13. A kit for a cover (100) for a universal joint (10) of a driveshaft (5), said kitcomprising: afirst section (110) having a first section first end (111), a first sectionsecond end (112) opposite the first section first end, a first section firstedge (113) extending between a first section first end first end-point and afirst section second end first end point, a first section second edge (114)extending between a first section first end second end-point and a firstsection second end second end-point, at least one first attachmentmember (410) extending from a first section inner surface, a firstlongitudinal axis (α1), and a first radius (r1);COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFTa second section (120) having a second section first end (121), a secondsection second end (122) opposite the second section first end, a secondsection first edge (123) extending between a second section first end firstend-point and a second section second end first end-point, a secondsection second edge (124) extending between a second section first end-point and a second section second end second end-point, at least onesecond attachment member (420) extending from a second section innersurface, a second longitudinal axis (α2), and a second radius (r2);a plurality of pads (300), each pad of the plurality of pads having a padsidewall (310) having a pad inner surface (311) and a pad outer surface(312), a pad attachment member (320) located in the pad outer surface,and an inner arch diameter (d2);at least two cover fasteners (130); andat least one driveshaft fastener (140); andwherein at least two pads of the plurality of pads have a different inner archdiameter; the pad attachment member of each pad of the plurality of pads is configured toconnect to a first attachment member of the at least one first attachment memberand / or a second attachment member of the at least one second attachmentmember; at least a first cover fastener of the at least two cover fasteners is configured toconnect the first section first edge to the second section first edge; at least a secondcover fastener of the at least two cover fasteners is configured to connect the firstsection second edge to the second section second edge; andthe at least one driveshaft fastener is configured to connect the cover to thedriveshaft or to a yoke of the driveshaft without any portion of the covercontacting the universal joint.

14. The kit of claim 13, wherein the first section first edge comprises a first sectionfirst flange (115), the second section first edge comprises a second section firstflange (125), and the first cover fastener is configured to connect the first sectionfirst edge to the second section first edge by passing through the first section firstflange and into the second section first flange or by passing through the secondsection first flange and into the first section first flange.COVER FOR A UNIVERSAL JOINT OF A DRIVESHAFT15. The kit of claims 13 or 14, wherein the first section second edge comprises a firstsection second flange (116), the second section second edge comprises a secondsection second flange (126), and the second cover fastener is configured toconnect the first section second edge to the second section second edge by passingthrough the first section second flange and into the second section second flangeor by passing through the second section second flange and into the first sectionsecond flange.

16. The kit of any of claims 13 to 15, wherein the first section comprises a first step-down (117) extending from a first position along a first length of the first sectionto the first section second end, and the second section comprises a second step-down (127) extending from a second position along a second length of the secondsection to the second section second end.

17. The kit of any of claims 13 to 16, wherein when the at least one driveshaft fasteneris configured to connect the cover to the yoke of the driveshaft, the first sectionsecond end comprises at least one first radial flange (118), the second sectionsecond end comprises at least one second radial flange (128), the at least onedriveshaft fastener comprises at least a first U-bolt (141) and a second U-bolt(142), the first U-bolt is configured to connect the at least one first radial flangeto the yoke, and the second U-bolt is configured to connect the at least one secondradial flange to the yoke.

18. The kit of any of claims 13 to 17, wherein the first section, the second section,and each pad of the plurality of pads are each independently composed of a semi-rigid polymeric material.

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