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S P E C I F I C A T I O N

TITLE

TWO PIECE PEDAL ROD AND METHOD OF MAKING SAME

RELATED APPLICATION This application is a continuation-in-part of my co-pending application Serial Number 08/045,654 filed April 9, 1993 entitled "Adjustable Pedal Rod and Method of Making Same. "

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates specifically to a pedal rod of the type utilized in the vehicular vehicle industry

and wherein devices are actuated by an operator exerting

force via a rod-like instrumentality interconnecting a foot or hand operated member and the operating mechanism of a vehicle such as the braking system of a car or truck.

The Prior Art

In my prior Patent No. 4,901,426, I have disclosed

and claimed the methods and equipment for forming threads or thread segments by pressing and without rotation in

a pedal rod construction.

In my prior patent issuing on co-pending allowed

application Serial Number 07/833,665, now issued as U. S. Patent 5,230,134, I have disclosed how the respective threaded portions of a mechanical joint may be formed in such a manner as to be matched or intentionally mismatched to afford a selective locking effect as two

threadedly related parts are joined together.

In my parent application, of which the present disclosure is a continuation-in-part, Serial Number 08/045,654 filed April 9, 1993, it was contemplated that there be provided an adjustable, preset, threaded and torqued pedal rod assembled to a mean dimension supplied

by the customer and then securely locked into firm assembly for utilization without further adjustment in

the assembly line of the customer.

SUMMARY OF THE INVENTION

In accordance with the principles of the invention,

it is contemplated that there be provided a two piece pedal rod which is strong and efficient and which can be

quickly and conveniently manufactured with great economy,

thereby providing a pedal rod unit which is price

competitive and entirely reliable for its intended

purpose.

The two separate pieces are a head part and a shaft part which are formed without any threads or screw thread segments whatsoever. Moreover, the head part may be made

of a different material than the shaft part, thereby

affording the possibility of selectively and

independently plating or coating one or the other of the component elements of the pedal rod assembly, thereby to protectably enhance the resistance of the part to environmental factors such as rust and corrosion by road

chemicals. Such coating or plating can also effect color

coding. For example, by so treating the head part selectively with a colored plating operation the parts of different original equipment manufacturers may be distinguished from one another, even though the parts are

produced on the same production line. Such optional

plating operation can be effected without the risk of

adversely affecting the assembly joints on the other

part.

The two separate parts are permanently bonded into

firm assembly with one another simply by press fitting and are locked together permanently by pressure crimping, thereby to provide a crimped joint having as many as six

separate crimping elements.

DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a pedal rod unit constructed in accordance with the principles of the present invention.

Figure 2 is an elevational view showing a side

elevation of the shaft part of the present invention, but

with parts broken away and with parts shown in cross-

section to illustrate additional details of the features

incorporated in the shaft part.

Figure 3 is an elevational view showing in side elevation the head part of the present invention prior to its joinder in assembly with the shaft part.

Figure 4 is a cross-sectional view taken on line IV-IV of Figure 3 and showing additional details of the head part.

Figure 5 is a cross-sectional view taken on line

V-V of Figure 3 and showing still additional structural

features of the head part.

Figure 6 is an enlarged fragmentary cross-sectional view showing the crimped joint after assembly of the two parts and the crimped joinder thereof.

Figure 7 is a cross- sectional view taken on line

VII-VII of Figure 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

This application is a continuation-in-part of my co-pending application Serial Number 08/045,654 filed

April 9, 1993 entitled "Adjustable Pedal Rod and Method

of Making Same."

It is believed that the method technology of the

present invention and the preferred sequencing of the manufacturing techniques will be understood from the description which follows.

A metal bar stock can be employed to provide both

of the two separate components, or two elements, of the pedal rod provided in accordance with this invention.

Thus, in the practice of the present invention, it

is my objective to provide a pedal rod such as that

illustrated in Figure 1 and identified generally at 10. The pedal rod 10 consists of two separate elements or parts constituting a rod or shaft part 11 and a head part 12. The head part 12 is a flat rolled steel exhibiting

the characteristics 1010 to 1020, or 8620 steel. This material is particularly suitable for conducting

automated punch press operations and I have found it to be particularly appropriate for use in making the head parts in accordance with the principles of the present

invention. It should be understood of course, that

persons of skill in the art might select a material of

a different formulation which would not be a departure

from the spirit of this invention. However, the specified material is designated as constituting the best

mode of my discovery.

For the rod or shaft elements in the performance

environment of an automotive braking assembly, I have selected material of Rockwell "B" 95-105 12L14 steel.

That material I have found to be particularly appropriate for machining and stamping operations, especially when

such operations are conducted on automated machinery as is generally contemplated in prescribing modern low cost

manufacturing techniques. Referring now to Figure 2, the rod or shaft part is formed by machining a rod-shaped cylindrical work

piece into an elongated cylindrically shaped body having

a ball 13 at its free end, adapted to cooperate with the

mechanism with which the pedal rod is associated. Extending axially away from the ball 13 is a reduced diameter shaft portion 14 which merges with a transition

stage formed as an outwardly tapered section 15 and

expanding to a larger diameter body portion which is of

uniform diametral size throughout its length as shown at

16 and extending to the end of the work piece. The body

portion 16 terminates in an end wall 17 which is disposed

to extend radially.

As is disclosed in one of my earlier applications, it is contemplated that there be formed by a stamping step a spring seating shoulder 18, the formation of which is quickly and conveniently afforded by displacing the

metal of the surface so that a plurality of projections form a seating shoulder extending radially outwardly of the body portion 16. It will be appreciated that the only machining step required to finish the rod or shaft element 11 is form the ball 13 and its related transition portions and a

seating recess 19 in the end wall 17 of the rod or shaft

element 11. The step of forming recess 19 is accomplished by drilling and reaming the recess, for example, on a multiple spindle screw machine, which may also be used to form the ball 13. The recess 19 is

essentially cylindrical in shape and extends inwardly of

the end wall 17 on a center line axis of the rod or shaft

part 11.

Turning now to Figures 3, 4 and 5, it will be noted that the head part 12 can be formed in a punch press

operation simply by punching in a single stroke the

configuration shown in Figure 3, namely, by providing a

main body portion 20 having a through opening 21 centrally disposed therein. A curved outer edge is shown at 22 disposed approximately in concentric spacing

relative to the opening 21 and terminating in spaced

parallel side walls 23 and 24. The side walls 23 and 24 terminate in a flat planar

end wall 25 from which projects at a central axial position a generally rectangular boss 26 having a rounded

pilot end 27. The opposite sides of the boss 26 are notched as at 28 and 29, to provide a relief space in

which crimped material may be displaced during a

subsequent assembly operation. It should be understood that the boss 26 is sized and shaped so that it can be received within the recess 19. It is not cylindrical.

Rather, it is essentially rectangular in cross-section.

However, it can be fitted within the recess 19 for the purposes which will be described in greater detail.

It will be appreciated that the rod or shaft

element 11 and the head part or element 12 constitute

first and second parts which may be axially advanced selectively to successively engage the boss 26 into the recess 19, thereby to accomplish assembly of the two parts. This assembly can be accomplished mechanically and

could be automated if so desired. However, one of the features of the present

invention is that the two different parts afford a technique of manufacture which enables selective color

coding or plating to be accomplished without adversely affecting the integrity of the assembled parts.

For example, some automobile manufacturers desire

to afford parts which are exposed to corrosion of road chemicals such as salt and other ice melting compounds

with special protection. Such manufacturers require that the head part of the pedal rod assembly, especially, be

plated or protectively coated, since it is the head part that projects outside of the protective assembly.

Since the head part 12 of the present invention is

made as a completely separated part, and is even made of

a material which is different than the material or stock

from which the rod or shaft part 11 is made, it is

possible to afford the original equipment manufacturer a plating or color coding option at a nominal cost, since the head parts can be separately plated, without any adverse effect on the structural and functional

characteristics of the rod or shaft element, and without

adding any cost to the manufacturing price of the rod or shaft element.

For example, the head parts may at this stage be subjected to a yellow die chromate plating procedure so

that they will not only be protectively plated and given

an increased protection against the potentially harmful effects of a tough operating environment but will also

be very distinctively colored, thereby serving to clearly and unmistakably identify the particular pedal rod of

which the plated head element is a part as that of a

specific customer.

As disclosed in my parent application pedal rods are operatively connected in the actuating train of a motion mechanism actuated by the operator of a vehicle.

The head shown at 12 is illustrated in a single bar form,

although those versed in the art will readily recognize that the head 12 could also take the form of a clevis, a form of pedal rod configuration often used by foreign manufacturers of motor vehicles, or a so-called offset

head, which some OEM automobile manufacturers prefer for

space accommodation reasons.

In any event, once the head part 12 is ready for assembly to the rod or shaft part 11, the boss 26 is inserted into the recess 19. In this regard, the rounded

end shown at 27 on the end of the boss 26 eases entry of

the generally rectangularly shaped boss into the

cylindrically shaped recess and facilitates the assembly,

particularly if such assembly operation is being effected

by automated machinery.

As will be evident from an inspection of Figures

6 and 7, the two parts are press fit together so that the

end wall 17 of the part 11 seats snugly up against the wall 25 of the part 12 and the boss 26 extends fully and

completely into the recess 19.

At this juncture, the first and second parts may

be permanently bonded and assembled together by pressure crimping at as many as six separate locations. Thus in

Figures 6 and 7, four circumferentially spaced crimps 30 are shown, each of which constitutes an axially extending elongated slot which displaces material

inwardly from the outer part 11 into a bonding relation

with the inwardly adjacent part 12. Since the assembly of the first and second parts relates the body portion

of the rod or shaft part as an outer part surrounding an inner part provided by the boss of the second part, it should be noted how the material from the body portion

16, or outer part, is actually displaced radially

inwardly into the notches 28 and 29 formed in the surface

of the boss 26, or inner part. Further, the other two

crimps displace material from the body portion 16 into

close bonding relation with the surfaces of the boss 26,

thereby placing the two parts in firm assembly with one another. To further insure good bonding, two additional spaced end crimps as shown at 31 may also be employed. The crimps 31 are disposed on diametrically

opposite sides of the body 16 right at the end wall 17. In effect, the crimped joint forms and functions

as recess and detent means which operate to bond the inner and outer parts into an integrated unitary assembly so that the two parts constitute a single pedal rod unit

exhibiting unusual strength and versatility, but capable

of being produced on modern machinery at reduced cost.

Although various minor modifications might be suggested by those skilled in the art, it should be

understood that I wish to embody within the scope of the patent warranted hereon all such modifications as

reasonably and properly come within the scope of my

contribution to the art.