Two piece pedal rod and method of making same

Claim 2

A pedal rod assembly made of a two part sub-assembly, and comprising, in combination, (a) a first metal part constituting a rod shaped and formed to define an elongated cylinder shaped rod having a ball at one end, a reduced diameter portion extending axially away from said ball, a tapered outwardly expanding transition portion, and a body portion extending axially therefrom and being of a uniform diameter throughout and terminating in a radially disposed end wall, said end wall having a nonthreaded recess formed therein, (b) a second metal part constituting a flat head part shaped and formed to define a body portion having a through opening extending therethrough and having an axially extending nonthreaded boss projecting from one end wall thereof which is sized and shaped to be complementarily received within said recess in said first part, (c) a crimped joint formed between the first and second parts after the boss of said second pan is inserted into the recess of the first pan and said end wall of said first part is seated against the end wall of the second part, said crimped joint comprising interfitted bonded together locking means formed by the displaced material projecting inwardly from the outer first pan into and against the adjoining recessed surfaces of the inner second part, whereby the first and second parts are united into an integral unitary pedal rod.

Claim 3

A pedal rod assembly made of a two part sub-assembly, and comprising, in combination, (a) a first part constituting a rod shaped and formed to define an elongated cylinder shaped rod having a ball at one end a reduced diameter portion extending axially away from said ball, a tapered outwardly expanding transition portion, and a body portion extending axially therefrom and being of a uniform diameter throughout and terminating in a radially disposed end wall, said end wall having a recess formed therein, (b) a second part constituting a flat head part shaped and formed to define a body portion having a through opening extending therethrough and having an axially extending boss projecting from one end wall thereof which is sized and shaped to be complementarily received within said recess in said first part, (c) a crimped joint formed between the first and second parts after the boss of said second part is inserted into the recess of the first part and said end wall of the second part, said crimped joint comprising interfitted bonded together locking means formed by displaced material projecting inwardly from the outer first part into and against the adjoining recessed surfaces of the inner second part, whereby the first and second pans are united into an integral unitary pedal rod, said second pan having formed thereon a plated coating of protective material to enhance resistance of said second part to adverse environmental factors.

Claim 4

A pedal rod assembly made of a two part sub-assembly, and comprising, in combination, (a) a first part constituting a rod shaped and formed to define an elongated cylinder shaped rod having a ball at one end a reduced diameter portion extending axially away from said ball, a tapered outwardly expanding transition portion, and a body portion extending axially therefrom and being of a uniform diameter throughout and terminating in a radially disposed end wall, said end wall having a recess formed therein, (b) a second part constituting a flat head part shaped and formed to define a body portion having a through opening extending therethrough and having an axially extending boss projecting from one end wall thereof which is sized and shaped to be complementarily received within said recess in said first part, (c) a crimped joint formed between the first and second parts after the boss of said second part is inserted into the recess of the first part and said end wall of the second part, said crimped joint comprising interfitted bonded together locking means formed by displaced material projecting inwardly from the outer first part into and against the adjoining recessed surfaces of the inner second part, whereby the first and second pans are united into an integral unitary pedal rod, said second pan having formed thereon a plated coating of protective material to enhance resistance of said second part to adverse environmental factors.

Claim 5

A pedal rod as defined in claim 2 wherein said first part is made of 12L14 steel material.

Claim 6

A pedal rod as defined in claim 2 wherein said second part is made of 1010-1020 flat rolled steel for effecting formation of said second part in a single stroke punching operation.

Claim 7

A pedal rod as defined in claim 2 wherein said plated coating is formed of a yellow die chromate.

Claim 8

A pedal rod as defined in claim 2 wherein the crimped joint comprises six separate crimps: (a) four in circumferentially spaced portions of the peripheral surface of the body portion of the first part inwardly adjacent the end wall of the first part, and (b) two in diametrically opposite sides of said first part at the end wall thereof.

Claim 9

A pedal rod comprising in combination, a metal rod part having a ball at one end and an elongated cylindrically shaped body portion terminating in a radial end wall, said body portion having an axially inwardly extending nonthreaded cylindrical recess formed in said radial end wall, a metal head part having an end wall and a projecting nonthreaded cylindrical boss extending from said end wall and complemental in diameter and length to said cylindrical recess for insertion in to the recess in said radial end wall, said head part having said boss inserted into said rod pan at said recess, thereby to form a sub-assembly wherein the rod pan is a first outer part and the head part is a second inner part, and a crimped joint between the inner and outer parts and comprising fitted together locking means bonding the rod part and the head pan into a unitary integrated unit pedal rod.

Claim 10

A pedal rod comprising in combination, a metal rod part having a ball at one end and an elongated cylindrically shaped body portion terminating in a radial end wall, said body portion having an axially inwardly extending nonthreaded cylindrical recess formed in said radial end wall, a metal head part having an end wall and a projecting nonthreaded cylindrical boss extending from said end wall and complemental in diameter and length to said cylindrical recess for insertion in to the recess in said radial end wall, said head part having said boss inserted into said rod pan at said recess, thereby to form a sub-assembly wherein the rod pan is a first outer part and the head part is a second inner part, and a crimped joint between the inner and outer parts and comprising fitted together locking means bonding the rod part and the head pan into a unitary integrated unit pedal rod.