WO2019099757A1

WO2019099757A1 - Tube yokes and method of forming tube yokes

Info

Publication number: WO2019099757A1
Application number: PCT/US2018/061408
Authority: WO
Inventors: Perry D. LANDIS; Ryan W. Laskey; Bao T. Luong; Paulo R. Schilling
Original assignee: Dana Automotive Systems Group, Llc
Priority date: 2017-11-16
Filing date: 2018-11-16
Publication date: 2019-05-23

Abstract

A tube yoke member and method of forming the tube yoke member. The method includes providing a tube blank and a mould having inner surfaces with a per- determined shape. The tube blank is then hydro-formed into a hydro-formed member with a pre-determined shape conforming to the inner surface of the mould. During the hydro-forming process, an amount of force is applied by a first and second actuator assembly attached to a first and second end portion of the tube blank. A first and second tube yoke member having a substantially tubular portion and a hydro-formed portion are then separated from the hydro-formed member. A first and second yoke arm opening is then formed in the first and second yoke arms of the first tube yoke member and a first and second yoke arm opening is then formed in the first and second yoke arms in the second tube yoke member.

Description

TUBE YOKES AND METHOD OF FORMING TUBE YOKES

CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims the benefit to U.S. Provisional Patent

Application No. 62/587,271 filed on November 16, 2017, which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to tube yokes for use in a universal joint assembly and a method of forming said tube yokes.

BACKGROUND OF THEDISCLOSURE

Conventional universal joint assemblies include the use of a first tube yoke member that is drivingly connected to a second tube yoke member via a journal cross. Typically, conventional tube yokes are manufactured by using one or more forging processes. The forging process involves the shaping of a metal component or billet by applying an amount of localized compressive forces to the billet to form the desired component. Once the component has been forged, the forged component (e.g. the tube yoke) typically must undergo one or more additional manufacturing processes, such as one or more heat treating and machining processes, before the forged tube yoke is completed. These additional manufacturing processes aid in increasing the overall costs associated with the manufacture and production of a forged tube yoke. Additionally, order to create the finished tube yokes for the universal joint assembly by using a forging process, it requires the use of specially trained personnel, specialized tooling, specialized machinery and relatively large facilities, all of which aids in increasing the overall costs associated with the manufacture and production of a forged tube yoke.

Furthermore, conventional forged tube yokes have a low stiffness to weight ratio. As a result, conventional forged tube yokes are heavier and require more material to make. The increased amount of material needed to achieve the desired stiffness for the forged tube yoke further aids in increasing the overall costs associated with the manufacture and production of a forged tube yoke. Additionally, the extra weight of the conventional forged tube yoke aids in increasing the overall weight of the vehicle which has a detrimental effect on the overall fuel efficiency of the vehicle.

It would therefore be advantageous to develop a tube yoke that is easier to consistently manufacturer, is more cost efficient, has a higher stiffness to weight ratio, has a higher manufacturing repeatability and has reduced quality control issues.

SUMMARY OF THE DISCLOSURE

The method of forming a tube yoke member according to an aspect of the disclosure where the first tube yoke member and the tube yoke member may be separated from the hydro-formed member by using one or more plasma cutting processes, one or more laser cutting processes and/or one or more water jet cutting processes.

According to any one of the previous aspects of the disclosure, the first and second yoke are openings in the first and second yoke arms of the first tube yoke member may be formed by using one or more flow drilling processes, one or more laser cutting processes, one or more water jet cutting processes, one or more machining processes and/or one or more drilling processes.

According to any one of the previous aspects of the disclosure, the hydro- formed member may have a first end portion, a second end portion, an intermediate portion, a top portion, a bottom portion, a first side and a second side. The first end portion of the top portion of the hydro-formed member may have a concave portion which transitions into a convex portion and the intermediate portion of the top portion of the hydro-formed member may have a first substantially convex portion and a second substantially convex portion disposed on opposing sides of a substantially flat portion. Additionally, second end portion of the top portion of the hydro-formed member may have a concave portion which transitions into a convex portion and the first end portion of the bottom portion of the hydro-formed member may have a concave portion which transitions into a convex portion. Furthermore, the intermediate portion of the bottom portion of v hydro-formed member may have a first substantially convex portion and a second substantially convex portion disposed on opposing sides of a substantially flat portion and the second end portion of the bottom portion of the hydro-formed member may have a concave portion which transitions into a convex portion. The first end portion of the first side of the hydro-formed member may have a convex portion interposed between a first concave portion and a second concave portion and the intermediate portion of the first side of the hydro-formed member may have a first convex portion and a second convex portion disposed on opposing sides of a substantially flat portion. The second end portion of the first side of the hydro-formed member may have a convex portion interposed between a first concave portion and a second concave portion and first end portion of the second side of the hydro-formed member may have a convex portion interposed between a first concave portion and a second concave portion. Still further, the intermediate portion of the second side of said hydro-formed member may have a first convex portion and a second convex portion disposed on opposing sides of a substantially flat portion and second end portion of the second side of the hydro-formed member has a convex portion interposed between a first concave portion and a second concave portion.

According to any one of the previous aspects of the disclosure, concave portion of the first end portion of the top portion of the hydro-formed member may be disposed a length Ll from a first end of the hydro-formed member. The concave portion of the second end portion of the top portion of the hydro-formed member may be disposed a length L2 from a second end of the hydro-formed member. Additionally, the concave portion of the first end portion of the bottom portion of the hydro-formed member may be disposed a length L4 from the first end of the hydro-formed member and the concave portion of the second end portion of the bottom portion of the hydro-formed member may be disposed a length L5 from the second end of the hydro-formed member. It is within the scope of this disclosure and as a non-limiting example that the lengths Ll, L2, L4 and L5 may be substantially equal to each other. According to any one of the previous aspects of the disclosure, the first concave portion of the first end portion of the first side of the hydro-formed member may be disposed a length L7 from the first end of the hydro-formed member. The first concave portion of the second end portion of the first side of the hydro-formed member may be disposed a length L8 from the second end of the hydro-formed member and the first concave portion of the first end portion of the second side of the hydro-formed member may be disposed a length L10 from the first end of the hydro-formed member.

Additionally, the first concave portion of the second end portion of the second side of the hydro-formed member may be disposed a length Ll 1 from the second end of the hydro-formed member. It is within the scope of this disclosure and as a non-limiting example that the lengths L7, L8, L10 and Ll 1 may be substantially equal to each other. As a non-limiting example, the lengths Ll, L2, L4 and L5 may be greater than the lengths L7, L8, L10 and Ll 1 of the hydro-formed member.

According to any one of the previous aspects of the disclosure, the first tube yoke member may be separated from the hydro-formed member by a first tube yoke member cut and the second tube yoke member may be separated from the hydro- formed member by a second tube yoke member cut.

According to any one of the previous aspects of the disclosure, the first tube yoke member may be separated from the hydro-formed member by a first tube yoke member cut and the second tube yoke member may be separated from the hydro- formed member by a second tube yoke member cut. The first tube yoke member cut may penetrate at least a portion of the first substantially convex portions, the substantially flat portions and the second substantially convex portions of the intermediate portions of the top and bottom portions of the hydro-formed member; the first convex portions, the second convex portions and the substantially flat portions of the intermediate portions of the first and second sides of the hydro-formed member; and the convex portions and the second concave portions of the first end portions of the first and second sides of the hydro-formed member. Additionally, the second tube yoke member cut may penetrate at least a portion of the first substantially convex portions, the substantially flat portions and the second substantially convex portions of the intermediate portions of the top and bottom portions of the hydro-formed member; the first convex portions, the second convex portions and the substantially flat portions of the intermediate portions of the first and second sides of the hydro-formed member; and the convex portions and the second concave portions of the second end portions of the first and second sides of the hydro-formed member.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the first tube yoke member may have a first protruding portion and a third protruding portion and the hydro-formed portion of the second tube yoke member may have a second protruding portion and fourth protruding portion.

According to any one of the previous aspects of the disclosure, at least a portion of the first protruding portion in the hydro-formed portion of the first tube yoke member may be disposed in the convex portion of the first end portion of the second side. At least a portion of the third protruding portion in the hydro-formed portion of the first tube yoke member may be disposed in the convex portion of the first end portion of the first side. Additionally, at least a portion of the second protruding portion in the hydro-formed portion of the second tube yoke member may be disposed in the convex portion of the second end portion of the second side. Furthermore, at least a portion of the fourth protruding portion in the hydro-formed portion of the second tube yoke member may be disposed in the convex portion of the second end portion of the first side.

According to any one of the previous aspects of the disclosure, first protruding portion in the hydro-formed portion of the first tube yoke member may be disposed proximate to an end of a first yoke arm receiving portion in the hydro-formed portion of the first tube yoke member. Additionally, the third protruding portion in the hydro- formed portion of the first tube yoke member may be disposed proximate to an end of a second yoke arm receiving portion in the hydro-formed portion of the first tube yoke member. Furthermore, the second protruding portion in the hydro-formed portion of the second tube yoke member may be disposed proximate to an end of a first yoke arm receiving portion in the hydro-formed portion of the second tube yoke member. Still further, the fourth protruding portion in the hydro-formed portion of the second tube yoke member may be disposed proximate to an end of a second yoke arm receiving portion in the hydro-formed portion of the second tube yoke member.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of said first tube yoke member may have a first axially extending portion and a second axially extending portion and the hydro-formed portion of the second tube yoke member may have a first axially extending portion and a second axially extending portion.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the first tube yoke member may have a first axially extending portion and a second axially extending portion and the hydro-formed portion of the second tube yoke member may have a first axially extending portion and a second axially extending portion. The first axially extending portion of the first tube yoke member may be interposed between a first yoke arm receiving portion in the hydro-formed portion of the first tube yoke member and the first protruding portion of the first tube yoke member. Additionally, second axially extending portion of the first tube yoke member may be interposed between a second yoke arm receiving portion in the hydro-formed portion of the first tube yoke member and the third protruding portion of the first tube yoke member. Furthermore, the first axially extending portion of the second tube yoke member may be interposed between a first yoke arm receiving portion in the hydro- formed portion of the second tube yoke member and the first protruding portion of the second tube yoke member. Still further, the second axially extending portion of the second tube yoke member may be interposed between a first yoke arm receiving portion in the hydro-formed portion of the second tube yoke member and the first protruding portion of the second tube yoke member.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the first tube yoke member may have a frustum portion and the hydro-formed portion of the second tube yoke member may have a frustum portion.

According to any one of the previous aspects of the disclosure, the frustum portion of the hydro-formed portion of the first tube yoke member may have one or more substantially flat portions and the frustum portion of the hydro-formed portion of the second tube yoke member may have one or more substantially flat portions.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the first tube yoke member may have one or more reinforcing portions and the hydro-formed portion of the second tube yoke member may have one or more reinforcing portions.

According to any one of the previous aspects of the disclosure, the one or more reinforcing portions in the hydro-formed portions of the first and second tube yoke members may be substantially egg-shaped, elliptical, ellipsoidal, oval, ovate and/or ovoid in shape.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the first tube yoke member may have one or more reinforcing portions and the hydro-formed portion of the second tube yoke member may have one or more reinforcing portions. At least a portion of the one or more reinforcing portions in the hydro-formed portion of the first tube yoke member may be disposed within the frustum portion, the first yoke arm and/or the second yoke arm of the first yoke member. Additionally, at least a portion of the one or more reinforcing portions in the hydro-formed portion of the second tube yoke member may be disposed within the frustum portion, the first yoke arm and/or the second yoke arm of the second yoke member.

According to any one of the previous aspects of the disclosure, the method may further include the steps of attaching at least a portion of a first fluid supply line to at least a portion of the first end portion of the tube blank and flowing an amount of fluid through the first fluid supply line into the tube blank. This aids in removing an amount of air from within the tube blank. Additionally, the method may further include the steps of attaching at least a portion of a second fluid supply line to at least a portion of the second end portion of the tube blank after and/or while flowing an amount of fluid into the tube blank through the first fluid supply line and flowing an amount of fluid through the first and/or second fluid supply lines into the tube blank. This aids in ensuring that all or substantially all of the air has been removed from within the tube blank prior to creating the hydro-formed member.

A tube yoke member having a substantially tubular portion and a hydro-formed portion. The hydro-formed portion of the tube yoke member defines a first yoke arm, a second yoke arm, a first yoke arm receiving portion and a second yoke arm receiving portion. The first yoke arm may have a first yoke arm opening formed therein and the second yoke arm may have a second yoke arm opening formed therein.

According to an aspect of the disclosure, the hydro-formed portion of the tube yoke member may have a first protruding portion and a third protruding portion that aids in preventing the first yoke arm and the second yoke arm from deforming. The first protruding portion may be disposed proximate an end of said first yoke arm receiving portion opposite the first and second yoke arm openings and third protruding portion may be disposed proximate an end of the second yoke arm receiving portion opposite the first and second yoke arm openings.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the tube yoke member, proximate said first yoke arm, may be disposed a length Ll from an end of the substantially tubular portion, opposite the hydro-formed portion. Additionally, the hydro-formed portion of the tube yoke member, proximate said second yoke arm, may be disposed a length L4 from the end of the substantially tubular portion, opposite the hydro-formed portion ft is within the scope of this disclosure and as a non-limiting example that the length Ll and L4 may be substantially equal to each other.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the tube yoke member, proximate said first protruding portion of said hydro-formed portion of said tube yoke member, may be disposed a length L7 from said end of the substantially tubular portion, opposite the hydro-formed portion.

Additionally, the hydro-formed portion of the tube yoke member, proximate said third protruding portion of said hydro-formed portion of said tube yoke member, may be disposed a length L10 from the end of the substantially tubular portion, opposite the hydro-formed portion. It is within the scope of this disclosure and as a non-limiting example that the lengths L7 and L10 may be substantially equal to each other. As a non-limiting example, the lengths Ll and L4 may be greater than the lengths L7 and L10.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the tube yoke member may further include a first axially extending portion and a second axially extending portion. The first axially extending portion of the tube yoke member may be interposed between the first yoke arm receiving portion in the hydro-formed portion of the tube yoke member and the first protruding portion of the tube yoke member. Additionally, the second axially extending portion of the tube yoke member may be interposed between the second yoke arm receiving portion in the hydro-formed portion of the tube yoke member and the third protruding portion of the tube yoke member.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of the tube yoke member may have a frustum portion. According to any one of the previous aspects of the disclosure, the frustum portion of the hydro-formed portion of the tube yoke member may have one or more substantially flat portions.

According to any one of the previous aspects of the disclosure, the hydro- formed portion of said tube yoke member has one or more reinforcing portions.

According to any one of the previous aspects of the disclosure, the one or more reinforcing portions in the hydro-formed portion of the tube yoke member may be substantially egg-shaped, elliptical, ellipsoidal, oval, ovate and/or ovoid in shape.

According to any one of the previous aspects of the disclosure, at least a portion of the one or more reinforcing portions in the hydro-formed portion of the tube yoke member may be disposed within the frustum portion, the first yoke arm and/or the second yoke arm of the yoke member.

According to any one of the previous aspects of the disclosure, at least a portion of the one or more reinforcing portions in the hydro-formed portion of the tube yoke member may be disposed on opposing sides of the first and/or second yoke arms of the tube yoke member.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present disclosure, will become readily apparent to those skilled in the art lfom the following detailed description when considered in light of the accompanying drawings in which:

FIG. 1 is a schematic top-plan view of a vehicle having one or more coupling assemblies according to an embodiment of the disclosure;

FIG. 2 is a schematic top-plan view of another vehicle having one or more coupling assemblies according to an embodiment of the disclosure;

FIG. 3 is a schematic top-plan view of yet another vehicle having one or more coupling assemblies according to an embodiment of the disclosure;

FIG. 4 is a flow-chart illustrating a method of forming a first and second member of a coupling assembly according to an embodiment of the disclosure;

FIG. 5 is a schematic perspective view of a tube blank according to an embodiment of the disclosure; FIG. 6 is a schematic perspective view of a hydro-formed member according to an embodiment of the disclosure illustrating a top portion and a second side of the hydro-formed member;

FIG. 7 is a schematic perspective view of the hydro-formed member illustrated in FIG. 6 illustrating a bottom portion and a first side of the hydro-formed member;

FIG. 8 is a schematic perspective view of the hydro-formed member illustrated in FIG. 6 having a first tube yoke member cut and a second tube yoke member cut according to an embodiment of the disclosure;

FIG. 9 is a schematic perspective view of the hydro-formed member illustrated in FIG. 7 having the first tube yoke member cut and the second tube yoke member cut according to an embodiment of the disclosure;

FIG. 10 is a schematic top-plan view of the first tube yoke member cut and the second tube yoke member cut in the top portion of the hydro-formed member illustrated in FIGS. 6 and 8 of the disclosure;

FIG. 11 is a schematic top-plan view of the first tube yoke member cut and the second tube yoke member cut in the bottom portion of the hydro-formed member illustrated in FIGS. 7 and 9 of the disclosure

FIG. 12 is a schematic perspective view of a first tube yoke member and a second tube yoke member according to an embodiment of the disclosure;

FIG. 13 is a schematic perspective view of the first and second tube yoke members illustrated in FIG. 12 having apertures formed therein according to an embodiment of the disclosure;

FIG. 14 is a schematic perspective view of a first tube yoke member and a second tube yoke member according to an alternative embodiment of the disclosure;

FIG. 15 is a schematic perspective view of a first tube yoke member and a second tube yoke member according to another embodiment of the disclosure; and

FIG. 16 is a schematic perspective view of a first tube yoke member and a second tube yoke member according to yet another embodiment of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also understood that the specific devices and processes illustrated in the attached drawings, and described in the specification are simply exemplary embodiments of the inventive concepts disclosed and defined herein. Hence, specific dimensions, directions or other physical characteristics relating to the various embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise.

It is within the scope of this disclosure, and as a non-limiting example, that the tube yokes disclosed herein may be used in automotive, off-road vehicle, all-terrain vehicle, construction, structural, marine, aerospace, locomotive, military, machinery, robotic and/or consumer product applications. Additionally, as a non-limiting example, the tube yokes disclosed herein may also be used in passenger vehicle, electric vehicle, hybrid vehicle, commercial vehicle and/or heavy vehicle applications.

FIG. 1 is a schematic top-plan view of a vehicle 2 having one or more coupling assemblies according to an embodiment of the disclosure. The vehicle 2 has an engine 4 which is drivingly connected to a transmission 6. A transmission output shaft 8 is drivingly connected to an end of the transmission 6 opposite the engine 4. The transmission 6 is a power management system which provides controlled application of the rotational power generated by the engine 4 by means of a gear box.

The transmission output shaft 8 is drivingly connected to a transfer case input shaft 10 which in turn is drivingly connected to a transfer case 12. The transfer case 12 is used to transfer the rotational power from the transmission 6 to a front axle system 14 and a tandem axle system 16 by utilizing a series of gears and drive shafts. The transfer case 12 includes a first transfer case output shaft 18 and a second transfer case output shaft 20.

A first drive shaft 22 extends from the first transfer case output shaft 18 to the forward axle system 14 of the vehicle 2. A first end portion 24 of the first drive shaft 22 is drivingly connected to an end of the first transfer case output shaft 18 opposite the transfer case 12 via a first coupling assembly 26. As a non-limiting example, the first coupling assembly 26 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint. A second end portion 28 of the first drive shaft 22 is drivingly connected to a second coupling assembly 30. As a non-limiting example, the second coupling assembly 30 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint. Drivingly connected to an end of the second coupling assembly 30, opposite the first drive shaft 22, is an end of a forward axle system input shaft 32. In accordance with an embodiment of the disclosure and as a non-limiting example, the forward axle system input shaft 32 is a forward axle differential input shaft, a coupling shaft, stub shaft or a forward axle differential pinion shaft. Drivingly connected to an end of the forward axle system input shaft 32, opposite the first drive shaft 22, is a forward axle differential 34. The forward axle differential 34 is a set of gears that allows the outer drive wheel(s) of the wheeled vehicle to rotate at a faster rate that the inner drive wheel(s). The rotational power is transmitted through the forward axle system 14 as described in more detail below.

The forward axle system 14 further includes a first forward axle half shaft 36 and a second forward axle half shaft 38. The first forward axle half shaft 36 extends substantially perpendicular to the forward axle system input shaft 32. A first end portion 40 of the first forward axle half shaft 36 is drivingly connected to a first forward axle wheel assembly 42 and a second end portion 44 of the first forward axle half shaft 36 is drivingly connected to an end of the forward axle differential 34. In accordance with an embodiment of the disclosure and as a non-limiting example, the second end portion 44 of the first forward axle half shaft 36 is drivingly connected to a forward axle differential side gear, a separate stub shaft, a separate coupling shaft, a first forward axle differential output shaft and/or a shaft that is formed as part of a forward axle differential side gear.

The second forward axle half shaft 38 also extends substantially perpendicular to the forward axle system input shaft 32. A first end portion 46 of the second forward axle half shaft 38 is drivingly connected to a second forward axle wheel assembly 48. A second end portion 50 of the second forward axle half shaft 38 is drivingly connected to an end of the forward axle differential 34 opposite the first forward axle half shaft 36. As a non-limiting example, the second end portion 50 of the second forward axle half shaft 38 is drivingly connected to a forward axle differential side gear, a separate stub shaft, a separate coupling shaft, a second forward axle differential output shaft and/or a shaft that is formed as part of a forward axle differential side gear.

An end of the second transfer case output shaft 20 is drivingly connected to an end of the transfer case 12 opposite the transfer case input shaft 10. A second drive shaft 52 extends from the second transfer case output shaft 20 to a forward tandem axle system 53 of the tandem axle system 16 having an inter-axle differential 55. A first end portion 54 of the second drive shaft 52 is drivingly connected to an end of the second transfer case output shaft 20, opposite the transfer case 12, via a third coupling assembly 56. As a non-limiting example, the third coupling assembly 56 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint.

According to an embodiment of the disclosure (not shown), the vehicle does not include a transfer case. In accordance with this embodiment of the disclosure (not shown), the transmission output shaft 8 is drivingly connected to an end of the second drive shaft 52 via the third coupling assembly 56. The rotational power is then transferred through the remainder of the drive-train of the vehicle 2 as described in more detail below.

A second end portion 58 of the second drive shaft 52 is drivingly connected to a fourth coupling assembly 60. As a non-limiting example, the coupling assembly 60 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint.

Drivingly connected to an end of the fourth coupling assembly 60, opposite the second drive shaft 52, is an end of a forward tandem axle system input shaft 62 of the forward tandem axle system 53. In accordance with an embodiment of the disclosure and as a non-limiting example, the forward tandem axle system input shaft 62 is an inter-axle differential input shaft, a coupling shaft, stub shaft or an inter-axle differential pinion shaft. The inter-axle differential 55 is a device that divides the rotational power generated by the engine 4 between the axles in a vehicle 2. The rotational power is transmitted through the forward tandem axle system as described in more detail below.

As illustrated in FIG. 1 of the disclosure, the inter-axle differential 55 is drivingly connected to a forward tandem axle differential 64 and a forward tandem axle system output shaft 66. The forward tandem axle differential 64 is a set of gears that allows the outer drive wheel(s) of a wheeled vehicle to rotate at a faster rate than the inner drive wheel(s).

The forward tandem axle system 53 further includes a first forward tandem axle half shaft 68 and a second forward tandem axle half shaft 70. The first forward tandem axle half shaft 68 extends substantially perpendicular to the second drive shaft 52. A first end portion 72 of the first forward tandem axle half shaft 68 is drivingly connected to a first forward tandem axle wheel assembly 74 and a second end portion 76 of the first forward tandem axle half shaft 68 is drivingly connected to an end of the forward tandem axle differential 64. As a non-limiting example, the second end portion 76 of the first forward tandem axle half shaft 68 is drivingly connected to a forward tandem axle differential side gear, a separate stub shaft, a separate coupling shaft, a first forward tandem axle differential output shaft and/or a shaft that is formed as part of a forward tandem axle differential side gear.

Extending substantially perpendicular to the second drive shaft 52 is the second forward tandem axle half shaft 70. A first end portion 78 of the second forward tandem axle half shaft 70 is drivingly connected to a second forward tandem axle wheel assembly 80 and a second end portion 82 of the second forward tandem axle half shaft 70 is drivingly connected to an end of the forward tandem axle differential 64 opposite the first forward tandem axle half shaft 68. As a non-limiting example, the second end portion 82 of the second forward tandem axle half shaft 70 is drivingly connected to a forward tandem axle differential side gear, a separate stub shaft, a separate coupling shaft, a second forward tandem axle differential output shaft and/or a shaft that is formed as part of a forward tandem axle differential side gear.

One end of the forward tandem axle system output shaft 66 is drivingly connected to a side of the inter-axle differential 55 opposite the second drive shaft 52. An end of the forward tandem axle system output shaft 66, opposite the inter-axle differential 55, is drivingly connected to a first end portion 84 of a third drive shaft 86 via a fifth coupling assembly 88. In accordance with an embodiment of the disclosure and as a non-limiting example, the fifth coupling assembly 88 is a universal joint, a U- joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint. The third drive shaft 86 drivingly connects the forward tandem axle system 53 to a rear tandem axle system 90 of the tandem axle system 16 of the vehicle 2.

A second end portion 92 of the third drive shaft 86 is drivingly connected to an end of a rear tandem axle system input shaft 94 via a sixth coupling assembly 96. As a non-limiting example, the sixth coupling assembly 94 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardv Snicer ioint. Drivingly connected to an end of the sixth coupling assembly 96, opposite the third drive shaft 86, is an end of a rear tandem axle input shaft 94. In accordance with an embodiment of the disclosure and as a non-limiting example, the rear tandem axle input shaft 94 is a rear tandem axle differential input shaft, a coupling shaft, stub shaft or a rear tandem axle differential pinion shaft. Drivingly connected to an end of the rear tandem axle input shaft 94, opposite the third drive shaft 86, is a rear tandem axle differential 98. The rear tandem axle differential 98 is a set of gears that allows the outer drive wheel(s) of the wheeled vehicle to rotate at a faster rate that the inner drive wheel(s). The rotational power is transmitted through the rear tandem axle system 90 as described in more detail below.

The rear tandem axle system further includes a first rear tandem axle half shaft 100 and a second rear tandem axle half shaft 102. The first rear tandem axle half shaft 100 extends substantially perpendicular to the rear tandem axle input shaft 94. A first end portion 104 of the first rear tandem axle half shaft 100 is drivingly connected to a first rear tandem axle wheel assembly 106 and a second end portion of the first rear tandem axle half shaft 100 is drivingly connected to an end of the rear tandem axle differential 98. As a non-limiting example, the second end portion 108 of the first rear tandem axle half shaft 100 is drivingly connected to a rear tandem axle differential side gear, a separate stub shaft, a separate coupling shaft, a first rear tandem axle differential output shaft and/or a shaft that is formed as part of a rear tandem axle differential side gear.

Extending substantially perpendicular to the rear tandem axle system input shaft 94 is the second rear tandem axle half shaft 102. A first end portion 110 of the second rear tandem axle half shaft 102 is drivingly connected to a second rear tandem axle wheel assembly 112. A second end portion 114 of the second rear tandem axle half shaft 102 is drivingly connected to an end of the rear tandem axle differential 98 opposite the first rear tandem axle half shaft 100. As a non-limiting example, the second end of the second rear tandem axle half shaft is drivingly connected to a rear tandem axle differential side gear, a separate stub shaft, a separate coupling shaft, a second rear tandem axle differential output shaft and/or a shaft that is formed as part of a rear tandem axle differential side gear. It is within the scope of this disclosure that one or more of the coupling assemblies 26, 30, 56, 60, 88 and/or 96 of the vehicle 2 may be a coupling assembly according to an embodiment of the disclosure.

FIG. 3 is a schematic top-plan view of a vehicle 200 having one or more coupling assemblies according to an alternative embodiment of the disclosure. The vehicle 200 has an engine 202 which is drivingly connected to a transmission 204. A transmission output shaft 206 is then drivingly connected to an end of the transmission 204 opposite the engine 202. As previously discussed, the transmission 204 is a power management system which provides controlled application of the rotational energy generated by the engine 202 by means of a gearbox.

The transmission output shaft 206 is drivingly connected to a transfer case input shaft 208 which in turn is drivingly connected to a transfer case 210. The transfer case 210 is used in four-wheel drive and/or all- wheel-drive (AWD) vehicles to transfer the rotational power from the transmission 204 to a forward axle system 212 and a rear axle system 214 by utilizing a series of gears and drive shafts. The transfer case 210 additionally allows the vehicle 200 to selectively operate in either a two-wheel drive mode of a four- wheel/ AWD mode. The transfer case 210 includes a first transfer case output shaft 216 and a second transfer case output shaft 218.

A first drive shaft 220 extends from the first transfer case output shaft 216 to the forward axle system 212 of the vehicle 200. A first end portion 222 of the first drive shaft 220 is drivingly connected to an end of the first transfer case output shaft 216, opposite the transfer case 210, via a first coupling assembly 224. As a non-limiting example, the first coupling assembly 224 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint. A second end portion 226 of the first drive shaft 220 is drivingly connected to a second coupling assembly 228. As a non-limiting example, the second coupling assembly 228 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint.

Drivingly connected to an end of the second coupling assembly 228, opposite the first drive shaft 220, is an end of a forward axle system input shaft 230. In accordance with an embodiment of the disclosure and as a non-limiting example, the forward axle system input shaft 230 is a forward axle differential input shaft, a coupling shaft, stub shaft or a forward axle differential pinion shaft. Drivingly connected to an end of the forward axle system input shaft 230, opposite the first drive shaft 220, is a forward axle differential 232 of the forward axle system 212. The forward axle differential 232 is a set of gears that allows the outer drive wheel(s) of the wheeled vehicle to rotate at a faster rate that the inner drive wheel(s). The rotational power is transmitted through the forward axle system 212 as described in more detail below.

The forward axle system 212 further includes a first forward axle half shaft 234 and a second forward axle half shaft 236. The first forward axle half shaft 234 extends substantially perpendicular to the forward axle system input shaft 230. A first end portion 238 of the first forward axle half shaft 234 is drivingly connected to a first forward axle wheel assembly 240 and a second end portion 242 of the first forward axle half shaft 234 is drivingly connected to an end of the forward axle differential 232. As a non-limiting example, the second end portion 242 of the first forward axle half shaft 234 is drivingly connected to a forward axle differential side gear, a separate stub shaft, a separate coupling shaft, a first forward axle differential output shaft and/or a shaft that is formed as part of a forward axle differential side gear.

Extending substantially perpendicular to the forward axle system input shaft 230 is the second forward axle half shaft 236. A first end portion 244 of the second forward axle half shaft 236 is drivingly connected to a second forward axle wheel assembly 246. A second end portion 248 of the second forward axle half shaft 236 is drivingly connected to an end of the forward axle differential 232 opposite the first forward axle half shaft 234. As a non-limiting example, the second end portion 248 of the second forward axle half shaft 236 is drivingly connected to a forward axle differential side gear, a separate stub shaft, a separate coupling shaft, a second forward axle differential output shaft and/or a shaft that is formed as part of a forward axle differential side gear.

An end of the second transfer case output shaft 218 is drivingly connected to an end of the transfer case 210 opposite the transfer case input shaft 208. A second drive shaft 250 extends from the second transfer case output shaft 218 to a rear axle differential 252 of the rear axle system 214 of the vehicle 200. A first end portion 254 of the second drive shaft 250 is drivingly connected to an end of the second transfer case output shaft 218, opposite the transfer case 210, via a third coupling assembly 256. As a non-limiting example, the third coupling assembly 256 is a universal joint, a U- joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint. A second end portion 258 of the second drive shaft 250 is drivingly connected to a fourth coupling assembly 260. As a non-limiting example, the fourth coupling assembly 260 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint.

Drivingly connected to an end of the fourth coupling assembly 260 is an end of a rear axle system input shaft 262. In accordance with an embodiment of the disclosure and as a non-limiting example, the rear axle system input shaft 262 is a rear axle differential input shaft, a coupling shaft, stub shaft or a rear axle differential pinion shaft. Drivingly connected to an end of the rear axle system input shaft 262, opposite the second drive shaft 250, is the rear axle differential 252. The rear axle differential 252 is a set of gears that allows the outer drive wheel(s) of the wheeled vehicle to rotate at a faster rate that the inner drive wheel(s). The rotational power is transmitted through the rear axle system 214 as described in more detail below.

The rear axle system 214 further includes a first rear axle half shaft 264 and a second rear axle half shaft 266. The first rear axle half shaft 264 extends substantially perpendicular to the rear axle system input shaft 262. A first end portion 268 of the first rear axle half shaft 264 is drivingly connected to a first rear axle wheel assembly 270 and a second end portion 270 of the first rear axle half shaft 264 is drivingly connected to an end of the rear axle differential 252. As a non-limiting example, the second end portion 270 of the first rear axle half shaft is drivingly connected to a rear axle differential side gear, a separate stub shaft, a separate coupling shaft, a first rear axle differential output shaft and/or a shaft that is formed as part of a rear axle differential side gear.

Extending substantially perpendicular to the rear axle system input shaft 262 is the second rear axle half shaft 266 of the rear axle system 214. A first end portion 272 of the second rear axle half shaft 266 is drivingly connected to a second rear axle wheel assembly 274. A second end portion 276 of the second rear axle half shaft 266 is drivingly connected to an end of the rear axle differential 252 opposite the first rear axle half shaft 264. As a non-limiting example, the second end portion 276 of the second rear axle half shaft 266 is drivingly connected to a rear axle differential side gear, a separate stub shaft, a separate coupling shaft, a second rear axle differential output shaft and/or a shaft that is formed as part of a rear axle differential side gear. It is within the scope of this disclosure that one or more of the coupling assemblies 224, 228, 256 and/or 260 may be a coupling assembly according to an embodiment of the disclosure.

FIG. 3 is a schematic top-plan view of a vehicle 300 having one or more coupling assemblies according to another embodiment of the disclosure. The vehicle 300 has an engine 302 which is drivingly connected to a transmission 304. A transmission output shaft 306 is then drivingly connected to an end of the transmission 304 opposite the engine 302. The transmission is a power management system which provides controlled application of the rotational power generated by the engine by means of a gear box.

A drive shaft 308 extends from the transmission output shaft 306 and drivingly connects the transmission 304 to a rear axle differential 311 of a rear axle system 310 of the vehicle 300. A first end portion 312 of the drive shaft 308 is drivingly connected to the end of the transmission output shaft 306, opposite the transmission 304, via a first coupling assembly 314. As a non-limiting example, the first coupling assembly 314 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint. A second end portion 316 of the drive shaft 308 is drivingly connected to a second coupling assembly 318. In accordance with an embodiment of the disclosure and as a non-limiting example, the second coupling assembly 318 is a universal joint, a U-joint, a universal coupling, a cardan joint, a double cardan joint, a Hooke’s joint, a Spicer joint or a Hardy Spicer joint.

Drivingly connected to an end of the second coupling assembly 318 is an end of a rear axle input shaft 320. As a non-limiting example, the rear axle input shaft 320 is a differential input shaft, a coupling shaft, stub shaft or a differential pinion shaft.

Drivingly connected to an end of the rear axle input shaft 320, opposite the drive shaft 308, is the rear axle differential 311 of the rear axle system 310 of the vehicle 300. The rear axle differential 311 is a set of gears that allows the outer drive wheel(s) of the wheeled vehicle to rotate at a faster rate that the inner drive wheel(s). The rotational power is transmitted through the rear axle system 310 as described in more detail below.

The rear axle system 310 further includes a first rear axle half shaft 322 and a second rear axle half shaft 324. The first rear axle half shaft 322 extends substantially perpendicular to the rear axle input shaft 320. A first end portion 326 of the first rear axle half shaft 322 is drivingly connected to a first rear axle wheel assembly 328 and a second end portion 330 of the first rear axle half shaft 322 is drivingly connected to an end of the rear axle differential 311. As a non-limiting example, the second end portion 330 of the first rear axle half shaft 322 is drivingly connected to a differential side gear, a separate stub shaft, a separate coupling shaft, a first rear axle differential output shaft and/or a shaft that is formed as part of a differential side gear.

Extending substantially perpendicular to the rear axle input shaft 320 is the second rear axle half shaft 324 of the rear axle system 310 of the vehicle 300. A first end portion 332 of the second rear axle half shaft 324 is drivingly connected to a second rear axle wheel assembly 334. A second end portion 336 of the second rear axle half shaft 324 is drivingly connected to an end of the rear axle differential 311 opposite the first rear axle half shaft 322. As a non-limiting example, the second end portion 336 of the second rear axle half shaft 324 is drivingly connected to a differential side gear, a separate stub shaft, a separate coupling shaft, a second rear axle differential output shaft and/or a shaft that is formed as part of a differential side gear.

It is within the scope of this disclosure that one or more of the coupling assemblies 314 and/or 318 may be a coupling assembly according to an embodiment of the disclosure.

FIGS. 4-13 illustrate a method of forming a first and second member of a coupling assembly 400 according to an embodiment of the disclosure. It is within the scope of this disclosure and as a non-limiting example that the method of forming a first and second member of a coupling assembly 400 may be one or more hydroforming processes. As best seen in FIG. 4 of the disclosure, the method of forming a first and second member of a coupling assembly 400 includes first providing a tube blank 402. In accordance with the embodiment of the disclosure illustrated in FIG. 5 and as a non-limiting example, the tube blank 404 has a first end portion 406, a second end portion 408, an inner surface 410 and an outer surface 412. The inner surface 410 and the outer surface 412 of the tube blank 404 defines a hollow portion 414 therein.

In order to form the first and second members of the coupling assembly, a mould having an inner surface is provided 416. The mould (not shown) has an inner surface (not shown) and an outer surface (not shown) defining a hollow portion (not shown) therein. It is within the scope of this disclosure that the mould (not shown) may be made of one or more pieces having a shaped inner surface (not shown) that provides a negative moulding surface for the tube blank 40(1. As a result, the shaped inner surface (not shown) of the one or more pieces of the mould (not shown) provide a substantially continuous inner surface defining the desired shape for the tube blank 404.

Once the mould has been provided 416, at least a portion of the tube blank will be inserted within at least a portion of the mould 418. It is within the scope of this disclosure and as a non-limiting example, that at least a portion of the tube blank 404 may be received and/or retained within at least a portion of the hollow interior portion (not shown) of the mould (mould). In accordance with the embodiment of the disclosure where the mould is made of a plurality of pieces, at least a portion of the mould is designed so as to receive and retain at least a portion of the tube blank 404. This will aid in ensuring that the tube blank does not move during the forming process.

In order to form the first and second members of the coupling assembly 400 a first fluid supply line may be attached 420 to at least a portion of the first end portion 406 of the tube blank 404. Additionally, at least a portion of a first actuator assembly may be attached 422 to at least a portion of the first end portion 406 of the tube blank 404 and/or to at least a portion of the first fluid supply line (not shown). The first actuator assembly (not shown) is designed to apply an amount of axial force onto the first end portion 406 of the tube blank 404. It is within the scope of this disclosure and as a non-limiting example that the first fluid supply line (not sown) may be integrally formed as part of the first actuator assembly (not shown) or may be integrally connected to at least a portion of the first actuator assembly (not shown).

According to an embodiment of the disclosure and as a non-limiting example, at least a portion of the first fluid supply line (not shown) may be sealingly engaged with at least a portion of the first end portion 406 of the tube blank 404. It is within the scope of this disclosure and as a non-limiting example that a nozzle (not shown) of the first fluid supply line (not shown) may include one or more sealing surfaces (not shown) that are complementary to one or more sealing surfaces (not shown) on the first end portion 406 of the tube blank 404. Once at least a portion of the one or more sealing surfaces (not shown) on the nozzle (not shown) of the first fluid supply line (not shown) are in direct contact with at least a portion of the one or more sealing surfaces (not shown) on the tube blank 404, the mechanical interference between the nozzle (not shown) and the tube blank 404 will create a sealing force sealing off the first end portion 406 of the tube blank 404. It is within the scope of this disclosure and as a non- limiting example that the one or more sealing surfaces (not shown) on the nozzle and/or the first end portion 406 of the tube blank 404 may be one or more chamfer portions and/or stepped portions that are capable of providing a mating relationship between the nozzle (not shown) and the first end portion 406 of the tube blank 404.

At least a portion of the first fluid supply line (not shown) may be in fluid communication with at least a portion of one or more reservoirs (not shown) having an amount of fluid therein. As a result, the hollow interior portion 414 of the tube blank 404 may be placed in fluid communication with the fluid contained within the one or more reservoirs (not shown). It is within the scope of this disclosure and as a nonlimiting example that the fluid within the one or more reservoirs (not shown) may be a water solution of a hydraulic fluid solution.

In accordance with an embodiment of the disclosure and as a non-limiting example, the first fluid supply line (not shown) may be in fluid communication with one or more first pumping assemblies (not shown). The one or more first pumping assemblies (not shown) aid in facilitating the transmission of an amount of the fluid from within the one or more reservoirs (not shown) and into the hollow portion 414 of the tube blank 404. Additionally, the one or more first pumping assemblies (not shown) aid in creating the fluid pressure needed to deform the tube blank 404 and create the hydro-formed member 434.

Once the first fluid supply line and/or the first actuator have been attached 420 and 422 to at least a portion of the first end portion 406 of the tube blank 404, an amount of fluid may be flown through the first fluid supply line 423 into the hollow portion 414 of the tube blank 404. This aids in removing an amount of compressible air from within the tube blank 404 before tube blank 404 is deformed as a result of the hydro-forming process 400. The inclusion of an amount of air within the hollow portion 414 of the tube blank 404 during the hydro-forming process 400 results in a hydro- formed member 434 that does not exactly conform to the surface defining the hollow interior of the mould (not shown). This results in a failed hydro-forming process 400 and/or as a hydro-formed member 434 with a reduced overall life and durability. As a result, it is therefore to be understood that the step of flowing an amount of fluid through the first fluid supply line 423 into the tube blank 404 aids in ensuring that hydro-formed member 434 is successfully formed by ensuring that the hydro-formed member 434 has a shape that conforms exactly to the surface defining the hollow interior of the mould (not shown).

A second fluid supply line may be attached 424 to at least a portion of the second end portion 408 of the tube blank 404. It is within the scope of this disclosure and as a non-limiting example that only one fluid supply line may be attached 420 or 424 to tube blank 404 or both the first and second fluid supply lines (not shown) may be attached 420 and 424 to the tube blank 404. In accordance with the embodiment of the disclosure where only one fluid supply line is attached 420 or 422 to the tube blank 404, the end of the tube blank 404 not connected to a fluid supply line will be blocked off or plugged with a plug member (not shown). As a non-limiting example, the first and/or the second fluid supply lines may be attached 420 and/or 422 to the first and second end portions 406 and 408 of the tube blank 404 respectively at a location outside the mould (not shown).

Additionally, it is within the scope of this disclosure and as a non-limiting example that at least a portion of a second actuator assembly may be attached 426 to at least a portion of the second end portion 408 of the tube blank 404 and/or to at least a portion of the second fluid supply line (not shown). The second actuator assembly (not shown) is designed to apply an amount of axial force onto the second end portion 408 of the tube blank 404. It is within the scope of this disclosure and as a non-limiting example that the second fluid supply line (not sown) may be integrally formed as part of the second actuator assembly (not shown) or may be integrally connected to at least a portion of the second actuator assembly (not shown).

According to an embodiment of the disclosure and as a non-limiting example, at least a portion of the second fluid supply line (not shown) may be sealingly engaged with at least a portion of the second end portion 408 of the tube blank 404. It is within the scope of this disclosure and as a non-limiting example that a nozzle (not shown) of the second fluid supply line (not shown) may include one or more sealing surfaces (not shown) that are complementary to one or more sealing surfaces (not shown) on the second end portion 408 of the tube blank 404. Once at least a portion of the one or more sealing surfaces (not shown) on the nozzle (not shown) of the second fluid supply line (not shown) are in direct contact with at least a portion of the one or more sealing surfaces (not shown) on the tube blank 404, the mechanical interference between the nozzle (not shown) and the tube blank 404 will create a sealing force sealing off the second end portion 408 of the tube blank 404. It is within the scope of this disclosure and as a non-limiting example that the one or more sealing surfaces (not shown) on the nozzle and/or the second end portion 408 of the tube blank 404 may be one or more chamfer portions and/or stepped portions that are capable of providing a mating relationship between the nozzle (not shown) and the second end portion 408 of the tube blank 404.

At least a portion of the second fluid supply line (not shown) may be in fluid communication with the one or more reservoirs (not shown) having an amount of the fluid stored therein. As a result, it is therefore to be understood that the hollow portion 414 of the tube blank 404 may be placed in fluid communication with the fluid contained within the one or more reservoirs (not shown) via the first and/or the second fluid supply lines (not shown).

In accordance with an embodiment of the disclosure and as a non-limiting example, the second fluid supply lines (not shown) may be in fluid communication with one or more second pump assemblies (not shown). The one or more second pump assemblies (not shown) aid in facilitating the transmission of an amount of the fluid from within the one or more reservoirs (not shown), through the second fluid supply line (not shown) and into the hollow portion 414 of the tube blank 404. Additionally, the one or more second pumping assemblies (not shown) aid in creating the fluid pressure needed to deform the tube blank 404 and create the hydro-formed member 434. It is within the scope of this disclosure and as a non-limiting example that the one or more first and second pump assemblies (not shown) connected to the first and second fluid supply lines (not shown) may be the same pumping assemblies or the one or more first pumping assemblies (not shown) connected to the first fluid supply line (not shown) may be separate and therefore different from the one or more second pumping assemblies (not shown) connected to the second fluid supply line (not shown).

Once the second fluid supply line and/or the second actuator has been attached 424 and 426 to at least a portion of the second end portion 408 of the tube blank 408, an amount of fluid may be flown through the first and/or second fluid supply lines (not shown) 427 into the hollow portion 414 of the tube blank 404. This aids in removing all or substantially all of the compressible air disposed within the hollow portion 414 of the tube blank 404 before tube blank 404 is deformed as a result of the hydro-forming process 400. It is therefore to be understood that the step of flowing an amount of fluid through the first and/or second fluid supply lines 427, after the first and second actuator assemblies (not shown) and the first and second fluid supply lines (not shown) have been attached 420, 422, 424 and 426 to the first and second end portions 406 and 408 of the tube blank 404, aids in ensuring that hydro-formed member 434 is successfully formed. As a result, the hydro-forming process 400 described herein has a high degree of repeatability and reliability to create a hydro-formed member 434 having a shape that conforms exactly to the surface defining the hollow interior of the mould (not shown).

As previously discussed herein, the one or more first and/or second pump assemblies (not shown) allow for the flowing 428 of the fluid at a pre-determined pressure from the one or more reservoirs (not shown) through the first and/or second fluid supply lines (not shown) and into the hollow portion 414 of the tube blank 404. The amount of fluid pressure generated by the one or more pump assemblies (not shown) is determined based on the thickness of the tube blank 404, the material of the tube blank 404, the type of fluid used and/or the shape of the inner surface(s) defining the hollow interior portion of the mould (not shown).

As the amount of pressure within the hollow portion 414 of the tube blank 404 increases, the inner and outer surfaces 410 and 412 of the tube blank 404 are translated outward (e.g. expanded) 430 toward the inner surface(s) defining the hollow interior portion of the mould (not shown). The portion of the tube blank 404 within the hollow interior portion (not shown) of the mould (not shown) will expand outward 430 until outer surface 412 of the tube blank 404 conforms to the shape of the inner surface(s) defining the hollow interior portion of the mould (not shown). Once the outer surface 412 of the tube blank 404 has fully conformed to the inner surface(s) of the mould (not shown), the one or more pump assemblies (not shown) are turned off and the pressure within the hollow portion 414 of the tube blank 404 drops.

It is within the scope of this disclosure and as a non-limiting example that the first and/or second actuator assemblies (not shown) may apply an amount of axial force 432 onto the first and/or second end portions 406 and 408 while the high pressure fluid is being flowed 428 within the hollow portion 414 of the tube blank 404. This will aid in ensuring that the tube blank 404 does not rupture while the tube blank 404 is expanded outward 430 due to the high pressure fluid within the hollow portion 414 of the tube blank 404. Typically, the tube blank 404 will rupture when the thickness of the tube blank 404 falls below a minimum threshold thickness. By applying an amount of axial force 432 onto the first and/or second end portions 406 and/or 408 of the tube blank 404, a hydro-formed member 434 can be produced having a pre-determined optimal operating thickness without rupturing. As a result, the thickness of the tube blank 404 can be increased by the application of an amount of force 432 onto the first and/or second end portions 404 and/or 406 of the tube blank 404 during the expansion 430 of the tube blank 404 with the high pressure fluid.

In accordance with an embodiment of the disclosure and as a non-limiting example, the expansion of the tube blank 430 to conform to the shape of the surface defining the hollow interior of the mould and the application of an amount of force 432 onto the first and/or second end portions 404 and 406 of the tube blank 404 may occur concurrently.

After the one or more pump assemblies (not shown) have been turned off, and the pressure within the first and/or second fluid supply lines (not shown) have normalized, the first and second fluid supply lines may be detached 436 from the hydro-formed member 434, the first and second actuators may be detached 436 from the hydro-formed member 434 and/or the hydro-formed member 434 may be removed 436 from the mould (not shown). As best seen in FIG. 6 of the disclosure, the hydro- formed member 434 has an inner surface 438, an outer surface 440, a first end portion 442, a second end portion 444 and an intermediate portion 446 interposed between the first end second end portions 442 and 444 of the hydro-formed member 434. The inner surface 438 and the outer surface 440 of the hydro-formed member 434 defines a hollow portion 448 therein. In accordance with the embodiment of the disclosure illustrated in FIGS. 6 and 7 and as a non-limiting example, the first end portion 442 of the hydro-formed member 434 has a first substantially cylindrical portion 450 and the second end portion 444 of the hydro-formed member 434 has a second substantially cylindrical portion 452.

As best seen in FIGS. 6 and 7 of the disclosure, at least a portion of the intermediate portion 446 of the hydro-formed member 434 includes a hydro-formed portion 454 having a top portion 456, a bottom portion 458, a first side 460 and a second side 462. In accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, the first end portion 442 of the top portion 456 has a concave portion 464 that transitions into a convex portion 466. At least a portion of the concave portion 464, opposite the convex portion 466 of the first end portion 442 of the top portion 456 of the hydro-formed member 434, is in direct contact with at least a portion of the first substantially cylindrical portion 450 of the hydro-formed member 434. In accordance with an embodiment of the disclosure and as a non-limiting example, the end of the concave portion 464, opposite the convex portion 466 of the first end portion 442 of the top portion 456 of the hydro-formed member 434, is disposed at a length Ll from a first end 468 of the hydro-formed member 434.

The intermediate portion 446 of the top portion 456 of the hydro-formed member 434 has a first substantially convex portion 470, a second substantially convex portion 474 and a substantially flat portion 472 interposed between the first and second convex portions 470 and 474 of the hydro-formed member 434. As best seen in FIG. 6 of the disclosure, at least a portion of the first substantially convex portion 470 of the top portion 456 is disposed directly adjacent to at least a portion of the first side 460 of the hydro-formed member 434. Additionally, at least a portion of the second substantially convex portion 474 of the top portion 456 is disposed directly adjacent to the second side 462 of the hydro-formed member 434.

In accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, the second end portion 444 of the top portion 456 has a concave portion 476 and a convex portion 478. At least a portion of the concave portion 476, opposite the convex portion 478 of the top portion 456 of the second end portion 444 of the hydro-formed member 434, is in direct contact with at least a portion of the second substantially cylindrical portion 452 of the hydro-formed member 434.

According to an embodiment of the disclosure and as a non-limiting example, the end of the concave portion 476, opposite the convex portion 478 of the top portion 456 of the second end portion 444 of the hydro-formed member 434, is disposed at a length L2 from a second end 480 of the hydro-formed member 434. It is within the scope of this disclosure and as a non-limiting example that the length L2 may be substantially equal to the length Ll of the hydro-formed member 434.

As best seen in FIG. 6 of the disclosure, the substantially flat portion 472 of the top portion 456 of the hydro-formed member 434 has a length L3. The length L3 of the substantially flat portion 472 of the top portion 456 of the hydro-formed member 434 extends from an end of the convex portion 466, opposite the concave portion 464 of the first end portion 442, to an end of the convex portion 478, opposite the concave portion 476 of the second end portion 444. It is within the scope of this disclosure and as a non- limiting example that the length L3 of the hydro-formed member 434 may be greater than the lengths Ll and/or L2 of the hydro-formed member 434.

According to the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, the first end portion 442 of the bottom portion 458 has a concave portion 482 that transitions into a convex portion 484. At least a portion of the concave portion 482, opposite the convex portion 484 of the first end portion 442 of the bottom portion 458 of the hydro-formed member 434, is in direct contact with at least a portion of the first substantially cylindrical portion 450 of the hydro-formed member 434. As best seen in FIG. 7 and as a non-limiting example, the end of the concave portion 482, opposite the convex portion 484 of the first end portion 442 of the bottom portion 458 of the hydro-formed member 434, is disposed at a length L4 from the first end 468 of the hydro-formed member 434. It is within the scope of this disclosure and as a nonlimiting example, that the length L4 of the hydro-formed member 434 may be substantially equal to the lengths Ll and/or L2 of the hydro-formed member 434.

The intermediate portion 446 of the bottom portion 458 of the hydro-formed member 434 has a first substantially convex portion 486, a second substantially convex portion 488 and a substantially flat portion 490 interposed between the first and second convex portions 486 and 488 of the hydro-formed member 434. As best seen in FIG. 7 of the disclosure, at least a portion of the first substantially convex portion 486 of the bottom portion 458 is disposed directly adjacent to at least a portion of the first side 460 of the hydro-formed member 434. Additionally, at least a portion of the second substantially convex portion 488 of the bottom portion 458 is disposed directly adjacent to the second side 462 of the hydro-formed member 434.

In accordance with the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, the second end portion 444 of the bottom portion 458 has a concave portion 492 and a convex portion 494. At least a portion of the concave portion 492, opposite the convex portion 494 of the bottom portion 458 of the second end portion 444 of the hydro-formed member 434, is in direct contact with at least a portion of the second substantially cylindrical portion 452 of the hydro-formed member 434. According to an embodiment of the disclosure and as a non-limiting example, the end of the concave portion 492, opposite the convex portion 494 of the bottom portion 458 of the second end portion 444 of the hydro-formed member 434, is disposed at a length L5 from the second end 480 of the hydro-formed member 434. It is within the scope of this disclosure and as a non-limiting example that the length L5 may be substantially equal to the lengths Ll, L2 and/or L4 of the hydro-formed member 434.

As best seen in FIG. 7 of the disclosure, the substantially flat portion 490 of the bottom portion 458 of the hydro-formed member 434 has a length L6. The length L6 of the substantially flat portion 490 of the bottom portion 458 of the hydro-formed member 434 extends from an end of the convex portion 484, opposite the concave portion 482 of the first end portion 442, to an end of the convex portion 494, opposite the concave portion 492 of the second end portion 444. It is within the scope of this disclosure and as a non-limiting example that the length L6 of the hydro-formed member 434 may be greater than the lengths Ll, L2, L4 and/or L5 of the hydro-formed member 434. Additionally, it is within the scope of this disclosure and as a non-limiting example, that the length L6 of the hydro-formed member 434 may be substantially equal to the length L3 of the hydro-formed member 434.

The first end portion 442 of the first side 460 of the hydro-formed member 434 has a first concave portion 496, a convex portion 498 and a second concave portion 500. At least a portion of the first concave portion 496 of the first end portion 442 of the first side 460 of the hydro-formed member 434, is in direct contact with at least a portion of the first substantially cylindrical portion 450 of the hydro-formed member 434. In accordance with the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, the end of the first concave portion 496, opposite the convex portion 498 of the first end portion 442 of the first side 460, is disposed at a length L7 from the first end 468 of the hydro-formed member 434. It is within the scope of this disclosure and as a non-limiting example, that the length L7 of the hydro-formed member 434 may be less than the lengths Ll, L2, L3, L4, L5 and/or L6 of the hydro- formed member 434.

In accordance with the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, at least a portion of the first concave portion 496 of the first end portion 442 of the first side 460 of the hydro-formed member 434 transitions into at least a portion of the concave portions 464 and 482 of the top and bottom portions 456 and 458 of the hydro-formed member 434. Additionally, in accordance with the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, at least a portion of the convex portion 498 of the first side 460 transitions into at least a portion of the convex portions 466 and 484 of the top and bottom portions 456 and 458 of the hydro-formed member 434.

As best seen in FIG. 7 of the disclosure and as a non-limiting example, at least a portion of the convex portion 498 of the first end portion 442 of the first side 460 of the hydro-formed member 434 includes a first protruding portion 502. The first protruding portion 502 aids in increasing the structural integrity of the hydro-formed member 434.

The intermediate portion 446 of the first side 460 of the hydro-formed member 434 has a first convex portion 504, a second convex portion 506 and a substantially flat portion 508 interposed between the first and second convex portions 504 and 506 of the hydro-formed member 434. As best seen in FIG. 7 of the disclosure, at least a portion of the first convex portion 504 of the first side 460 is disposed directly adjacent to at least a portion of the top portion 456 of the hydro-formed member 434. At least a portion of the first convex portion 504 of the first side 460 transitions into at least a portion of the first substantially convex portion 470 of the top portion 456 of the hydro- formed member 434. Additionally, at least a portion of the second convex portion 506 of the first side 460 is disposed directly adjacent to the bottom portion 458 of the hydro-formed member 434. At least a portion of the second convex portion 506 of the first side 460 transitions into at least a portion of the first substantially convex portion 486 of the bottom portion 458 of the hydro-formed member 434.

In accordance with the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, the second end portion 444 of the first side 460 has a first concave portion 510, a convex portion 512 and a second concave portion 514. At least a portion of the first concave portion 510 of the second end portion 444 of the first side 460 of the hydro-formed member 434, is in direct contact with at least a portion of the second substantially cylindrical portion 452 of the hydro-formed member 434. In accordance with the embodiment of the disclosure illustrated in FIG. 7 and as a non- limiting example, the end of the first concave portion 510, opposite the convex portion 512 of the second end portion 444 of the first side 460, is disposed at a length L8 from the second end 480 of the hydro-formed member 434. It is within the scope of this disclosure and as a non-limiting example, that the length L8 of the hydro-formed member 434 may be less than the lengths Ll, L2, L3, L4, L5 and/or L6 of the hydro- formed member 434. Additionally, it is within the scope of this disclosure and as a non-limiting example that the length L8 of the hydro-formed member 434 may be substantially equal to the length L7 of the hydro-formed member 434.

According to the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, at least a portion of the first concave portion 510 of the second end portion 444 of the first side 460 of the hydro-formed member 434 transitions into at least a portion of the concave portions 476 and 492 of the top and bottom portions 456 and 458 of the hydro-formed member 434. Additionally, in accordance with the embodiment of the disclosure illustrated in FIG. 7 and as a non-limiting example, at least a portion of the convex portion 512 of the first side 460 transitions into at least a portion of the convex portions 478 and 494 of the top and bottom portions 456 and 458 of the hydro-formed member 434.

As best seen in FIG. 7 of the disclosure and as a non-limiting example, at least a portion of the convex portion 512 of the second end portion 444 of the first side 460 of the hydro-formed member 434 includes a second protruding portion 516. The second protruding portion 516 aids in increasing the structural integrity of the hydro-formed member 434.

The substantially flat portion 508 of the first side 460 of the hydro-formed member 434 is disposed within a recessed portion 517 in the first side 460 of the hydro- formed member 434. Additionally, the substantially flat portion 508 of the first side 460 of the hydro-formed member 434 has a length L9. The length L9 of the

substantially flat portion 508 of the first side 460 of the hydro-formed member 434 extends from an end of the second convex portion 500, opposite the concave portion 498 of the first end portion 442, to an end of the convex portion 514, opposite the concave portion 512 of the second end portion 444. It is within the scope of this disclosure and as a non-limiting example that the length L9 of the hydro-formed member 434 may be less than the lengths L3 and/or L6 of the hydro-formed member 434.

As best seen in FIG. 6 of the disclosure, the first end portion 442 of the second side 462 of the hydro-formed member 434 has a first concave portion 518, a convex portion 520 and a second concave portion 522. At least a portion of the first concave portion 510 of the first end portion 442 of the second side 462 of the hydro-formed member 434, is in direct contact with at least a portion of the second substantially cylindrical portion 452 of the hydro-formed member 434. In accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, the end of the first concave portion 518, opposite the convex portion 520 of the first end portion 442 of the second side 462, is disposed at a length L10 from the first end 468 of the hydro-formed member 434. It is within the scope of this disclosure and as a non- limiting example, that the length L10 of the hydro-formed member 434 may be less than the lengths Ll, L2, L3, L4, L5, L6 and/or L9 of the hydro-formed member 434. Additionally, it is within the scope of this disclosure and as a non-limiting example that the length L10 of the hydro-formed member 434 may be substantially equal to the lengths L7 and/or L8 of the hydro-formed member 434.

In accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, at least a portion of the first concave portion 518 of the first end portion 442 of the second side 462 of the hydro-formed member 434 transitions into at least a portion of the concave portions 464 and 482 of the top and bottom portions 456 and 458 of the hydro-formed member 434. Additionally, in accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, at least a portion of the convex portion 520 of the second side 462 transitions into at least a portion of the convex portions 466 and 484 of the top and bottom portions 456 and 458 of the hydro-formed member 434.

As best seen in FIG. 6 of the disclosure and as a non-limiting example, at least a portion of the convex portion 520 of the first end portion 442 of the second side 462 of the hydro-formed member 434 includes a third protruding portion 524. The third protruding portion 524 aids in increasing the structural integrity of the hydro-formed member 434.

The intermediate portion 446 of the second side 462 of the hydro-formed member 434 has a first convex portion 526, a second convex portion 528 and a substantially flat portion 530 interposed between the first and second convex portions 526 and 528 of the hydro-formed member 434. As best seen in FIG. 6 of the disclosure, at least a portion of the first convex portion 526 of the second side 462 is disposed directly adjacent to at least a portion of the bottom portion 458 of the hydro-formed member 434. At least a portion of the first convex portion 526 of the second side 462 transitions into at least a portion of the first substantially convex portion 486 of the bottom portion 458 of the hydro-formed member 434. Additionally, at least a portion of the second convex portion 528 of the second side 462 is disposed directly adjacent to the top portion 456 of the hydro-formed member 434. At least a portion of the second convex portion 528 of the second side 462 transitions into at least a portion of the second substantially convex portion 474 of the top portion 456 of the hydro-formed member 434.

In accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, the second end portion 444 of the second side 462 has a first concave portion 532, a convex portion 534 and a second concave portion 536. At least a portion of the first concave portion 532 of the second end portion 444 of the second side 462 of the hydro-formed member 434, is in direct contact with at least a portion of the second substantially cylindrical portion 452 of the hydro-formed member 434. In accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non- limiting example, the end of the first concave portion 532, opposite the convex portion 534 of the second end portion 444 of the second side 462, is disposed at a length LI 1 from the second end 480 of the hydro-formed member 434. It is within the scope of this disclosure and as a non-limiting example, that the length LI 1 of the hydro-formed member 434 may be less than the lengths Ll, L2, L3, L4, L5, L6 and/or L9 of the hydro-formed member 434. Additionally, it is within the scope of this disclosure and as a non-limiting example that the length Ll 1 of the hydro-formed member 434 may be substantially equal to the lengths L7, L8 and/or LIO of the hydro-formed member 434.

According to the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, at least a portion of the first concave portion 532 of the second end portion 444 of the second side 462 of the hydro-formed member 434 transitions into at least a portion of the concave portions 476 and 492 of the top and bottom portions 456 and 458 of the hydro-formed member 434. Additionally, in accordance with the embodiment of the disclosure illustrated in FIG. 6 and as a non-limiting example, at least a portion of the convex portion 534 of the second side 462 transitions into at least a portion of the convex portions 478 and 494 of the top and bottom portions 456 and 458 of the hydro-formed member 434.

As best seen in FIG. 6 of the disclosure and as a non-limiting example, at least a portion of the convex portion 534 of the second end portion 444 of the second side 462 of the hydro-formed member 434 includes a fourth protruding portion 538. The fourth protruding portion 538 aids in increasing the structural integrity of the hydro-formed member 434 The substantially flat portion 530 of the second side 462 of the hydro-formed member 434 is disposed within a recessed portion 540 in the second side 462 of the hydro-formed member 434. Additionally, the substantially flat portion 530 of the second side 462 of the hydro-formed member 434 has a length L12. The length L12 of the substantially flat portion 530 of the second side 462 of the hydro-formed member 434 extends from an end of the second convex portion 522, opposite the concave portion 520 of the first end portion 442, to an end of the convex portion 536, opposite the concave portion 534 of the second end portion 444. It is within the scope of this disclosure and as a non-limiting example that the length L12 of the hydro-formed member 434 may be less than the lengths L3 and/or L6 of the hydro-formed member 434. Additionally, it is within the scope of this disclosure that the length L12 of the hydro-formed member 434 may be substantially equal to the length L9 of the hydro- formed member 434.

As illustrated in FIGS. 4, 8 and 9 of the disclosure, once the hydro-formed member 434 has been removed 436 from the mould (not shown), a first tube yoke member 542 and/or second tube yoke member 544 are separated 546 from the hydro- formed member 434. According to an embodiment of the disclosure and as a nonlimiting example, at least a portion of the hydro-formed member 434 may be retained within a retention member (not shown) and held in a stationary position while the first and/or the second tube yoke members 542 and/or 544 are separated 546 from the hydro formed member 434. In accordance with an alternative embodiment of the disclosure and as a non-limiting example, at least a portion of the hydro-formed member 434 is retained within a retaining member (not shown) and moved as the first and/or second tube yoke members 542 and/or 544 are separated 546 from the hydro-formed member 434. It is within the scope of this disclosure and as a non-limiting example that the first and/or second tube yoke members 542 and/or 544 may be separated 546 from the hydro-formed member 434 by using one or more plasma cutting processes, one or more laser cutting processes and/or one or more water jet cutting processes.

A first tube yoke member cut 548 separates 546 the first tube yoke member 542 from the hydro-formed member 434 and creates a first yoke arm 586 and a second yoke arm 588 of the first tube yoke member 542. As best seen in FIGS. 8 and 9 of the disclosure, the first tube yoke member cut 548 penetrates at least a portion of the first substantially convex portion 470, the substantially flat portion 472 and the second substantially convex portion 474 of the top portion 456, the first substantially convex portion 486, the second substantially convex portion 488 and the substantially flat portion 490 of the bottom portion 458 of the hydro-formed member 434. Additionally, as a non-limiting example, the first tube yoke member cut 548 penetrates at least a portion of the first convex portion 504, the second convex portion 506 and the substantially flat portion 508 of the first side 460, the first convex portion 526, the second convex portion 528 and substantially flat portion 536 of the second side 462 of the hydro-formed member 434. Furthermore, as a non-limiting example, the first tube yoke member cut 548 penetrates at least a portion of the convex portion 498 and the second concave portion 500 of the first end portion 442 of the first side 460 and at least a portion of the convex portion 520 and the second concave portion 522 of the first end portion 442 of the second side 462 of the hydro-formed member 434.

A second tube yoke member cut 550 separates 546 the second tube yoke member 544 from the hydro-formed member 434 and creates a first yoke arm 590 and a second yoke arm 592 of the second tube yoke member 544. As best seen in FIGS. 8 and 9 of the disclosure, the second tube yoke member cut 550 penetrates at least a portion of the first substantially convex portion 470, the substantially flat portion 472 and the second substantially convex portion 474 of the top portion 456, the first substantially convex portion 486, the second substantially convex portion 488 and the substantially flat portion 490 of the bottom portion 458 of the hydro-formed member 434.

Additionally, as a non-limiting example, the second tube yoke member cut 550 penetrates at least a portion of the first convex portion 504, the second convex portion 506 and the substantially flat portion 508 of the first side 460, the first convex portion 526, the second convex portion 528 and substantially flat portion 536 of the second side 462 of the hydro-formed member 434. Furthermore, as a non-limiting example, the second tube yoke member cut 550 penetrates at least a portion of the convex portion 512 and the second concave portion 514 of the second end portion 444 of the first side 460 and at least a portion of the convex portion 534 and the second concave portion 536 of the second end portion 444 of the second side 462 of the hydro-formed member 434.

Once the first tube yoke 542 and the second tube yoke 544 have been separated 546 from the hydroformed member 434 by the first and second tube yoke member cuts 548 and 550, the remaining portion(s) of the hydro-formed portion 454 may be recycled.

As best seen in FIG. 10 of the disclosure, the first tube yoke member cut 548 on the top portion 456 of the hydro-formed member 434 creates a first radiused portion 552, a second radiused portion 554 and a third radiused portion 556 of the first yoke arm 586 of the first tube yoke member 542. The second radiused portion 554 is interposed between the first and third radiused portions 552 and 556 of the first yoke arm 586 of the first tube yoke member 542. In accordance with the embodiment of the disclosure illustrated in FIG. 10 and as a non-limiting example, the first radiused portion 552 has a radius Rl, the second radiused portion 554 has a radius R2 and the third radiused portion 556 has a radius R3. As best seen in FIG. 10 of the disclosure, the radius R2 of the first yoke arm 586 of the first tube yoke member 542 is less than the radii Rl and R3 of the first yoke arm 586. It is within the scope of this disclosure and as a non-limiting example that the first radii Rl and the second radii R2 of the first yoke arm 586 of the first tube yoke member 542 may be substantially equal to one another.

The second tube yoke member cut 550 on the top portion 456 of the hydro- formed member 434 creates a first radiused portion 558, a second radiused portion 560 and a third radiused portion 562 for the first yoke arm 590 of the second tube yoke member 544. As best seen in FIG. 10 of the disclosure, the second radiused portion 560 of the second tube yoke member cut 550 is interposed between the first radiused portion 558 and the third radiused portion 562 of the first yoke arm 590 of the second tube yoke member 544. In accordance with the embodiment of the disclosure illustrated in FIG. 10 and as a non-limiting example, the first radiused portion 558 has a radius R4, the second radiused portion 560 has a radius R5 and the third radiused portion 562 has a radius R6. As best seen in FIG. 10 of the disclosure, the radius R5 of the first yoke arm 590 of the second tube yoke member 544 is less than the radii R4 and R6 of the first yoke arm 590. It is within the scope of this disclosure and as a non-limiting example that the first radii R4 and the second radii R6 of the first yoke arm 590 of the second tube yoke member 544 may be substantially equal to one another.

As best seen in FIG. 11 of the disclosure, the first tube yoke member cut 548 on the bottom portion 458 of the hydro-formed member 434 creates a fourth radiused portion 564, a fifth radiused portion 566 and a sixth radiused portion 568 of the second yoke arm 588 of the first tube yoke member 542. The second radiused portion 566 is interposed between the fourth and sixth radiused portions 564 and 568 of the second yoke arm 588 of the first tube yoke member 542. In accordance with the embodiment of the disclosure illustrated in FIG. 11 and as a non-limiting example, the fourth radiused portion 564 has a radius R7, the fifth radiused portion 566 has a radius R8 and the sixth radiused portion 568 has a radius R9. As best seen in FIG. 11 of the disclosure, the radius R8 of the second yoke arm 588 of the first tube yoke member 542 is less than the radii Rl, R3, R7 and/or R9 of the second yoke arm 588. It is within the scope of this disclosure and as a non-limiting example that the radii Rl, R3, R7 and/or R9 of the second yoke arm 588 of the first tube yoke member 542 may be substantially equal to one another. Additionally, it is within the scope of this disclosure and as a non- limiting example, that the radii R2 and R8 of the second yoke arm 588 of the first tube yoke member 542 may be substantially equal to one another.

The second tube yoke member cut 550 on the bottom portion 458 of the hydro- formed member 434 creates a fourth radiused portion 570, a fifth radiused portion 572 and a sixth radiused portion 574 of the second yoke arm 592 of the second tube yoke member 544. The second radiused portion 572 is interposed between the fourth and sixth radiused portions 570 and 564 of the second yoke arm 592 of the second tube yoke member 544. In accordance with the embodiment of the disclosure illustrated in FIG. 11 and as a non-limiting example, the fourth radiused portion 570 has a radius R10, the fifth radiused portion 572 has a radius Rl 1 and the sixth radiused portion 572 has a radius R12. As best seen in FIG. 11 of the disclosure, the radius Rl 1 of the second yoke arm 592 of the second tube yoke member 544 is less than the radii R4, R6, R10 and/or R12 of the second yoke arm 592. It is within the scope of this disclosure and as a non-limiting example that the radii R4, R6, R10 and/or R12 of the second yoke arm 592 of the second tube yoke member 544 may be substantially equal to one another. Additionally, it is within the scope of this disclosure and as a non-limiting example, that the radii R5 and Rl 1 of the second yoke arm 592 of the second tube yoke member 544 may be substantially equal to one another.

As best seen in FIG. 12 of the disclosure, the first tube yoke member 542 is a unitary hydro-formed member having an inner surface 576, an outer surface 578, a first end portion 580, a second end portion 582 and an intermediate portion 584 interposed between the first end second end portions 580 and 582 of the first tube yoke member 542. The first end portion 580 of the first tube yoke member 542 includes the first substantially cylindrical portion 450 and the hydro-formed portion 454 extends outward from at least a portion of the intermediate portion 584 and/or the second end portion 582 of the first tube yoke member 542. Additionally, the first tube yoke member 542 includes the first protruding portion 502 and the third protruding portion 524 of the hydro-formed portion 454.

It is to be understood that the first and third protruding portions 502 and 524 of the first tube yoke member 542 aid in providing structural support for the first tube yoke member 542 by increasing the structural rigidity of the first tube yoke member 542. As a non-limiting example, this increase in structural rigidity may be achieved by providing the first tube yoke member 542 with an area of increased thickness at the location of the first and third protruding portions 502 and 524. By increasing the structural rigidity of the first tube yoke member 542, the first tube yoke member 542 is able to experience a wider array of forces in operation without failing. Furthermore, it is to be understood that the first and third protruding portions 502 and 524 of the first tube yoke member 542 aid in providing the first and second yoke arms 586 and 588 with the structural support needed to resist deformation when in operation. Therefore, the first and third protruding portions 502 and 524 of the first tube yoke member 542 aid in increasing the overall life and durability of the first tube yoke member 542 and are critical in providing a hydro-formed first tube yoke member 542 that is capable of withstanding the forces exerted onto the first tube yoke member 542 when in operation.

As best seen in FIG. 12 of the disclosure, the second tube yoke member 544 is a unitary hydro-formed member having an inner surface 594, an outer surface 596, a first end portion 598, a second end portion 600 and an intermediate portion 602 interposed between the first end second end portions 598 and 602 of the second tube yoke member 544. The first end portion 598 of the second tube yoke member 544 includes the second substantially cylindrical portion 452 and the hydro-formed portion 454 extends outward from at least a portion of the intermediate portion 602 and/or the second end portion 600 of the second tube yoke member 544. Additionally, the second tube yoke member 544 includes the second protruding portion 516 and the fourth protruding portion 538 of the hydro-formed portion 454.

It is to be understood that the second and fourth protruding portions 516 and 538 of the second tube yoke member 544 aid in providing structural support for the second tube yoke member 544 by increasing the structural rigidity of the second tube yoke member 545. As a non-limiting example, this increase in structural rigidity may be achieved by providing the second tube yoke member 544 with an area of increased thickness at the location of the second and fourth protruding portions 516 and 538. By increasing the structural rigidity of the second tube yoke member 544, the second tube yoke member 544 is able to experience a wider array of forces in operation without failing. Furthermore, it is to be understood that the second and fourth protruding portions 516 and 538 of the second tube yoke member 544 aid in providing the first and second yoke arms 590 and 592 with the structural support needed to resist deformation when in operation. Therefore, the second and fourth protruding portions 516 and 538 of the second tube yoke member 544 aid in increasing the overall life and durability of the second tube yoke member 544 and are critical in providing a hydro-formed second tube yoke member 544 that is capable of withstanding the forces exerted onto the second tube yoke member 544 when in operation.

According to the embodiment illustrated in FIG. 13 of the disclosure and as a non-limiting example, the first tube yoke member 542 may include a first yoke arm receiving portion 587 and a second yoke arm receiving portion 589. The first and second yoke arm receiving portions 587 and 589 may be of a size and shape to receive at least a portion of the first and second yoke arms 590 and 592 of the second tube yoke member 544. As best seen in FIG. 13 of the disclosure and as a non-limiting example, the first and second yoke arm receiving portions 587 and 589 may extend inward into the first tube yoke member 542 toward the first end portion 580 of the first tube yoke member 542. As best seen in FIG. 13 and as a non-limiting example, at least a portion of the first and third protruding portions 502 and 524 of the first tube yoke member 542 may be disposed proximate to an end of the first and second yoke arm receiving portions 587 and 589, opposite an outermost end of the first and second yoke arms 586 and 588 of the first tube yoke member 542. By locating the first and third protruding portions 502 and 524 in this location, it aids in ensuring that the first and second yoke arms 586 and 588 of the first tube yoke member 542 have the structural rigidity needed in order to resist deformation when in operation. It is therefore to be understood that the location of the first and third protruding portions 502 and 524 is critical to ensuring that the first and second yoke arms 586 and 588 of the first tube yoke member 542 are capable of withstanding the exerted thereon when in operation. As a result, it is therefore to be understood that the first tube yoke member 542 includes a substantially tubular portion 595 and a hydro-formed portion 597. It is within the scope of this disclosure and as a non-limiting example that the first protruding portion 502, the second protruding portion 524, the first yoke arm receiving portion 587, the second yoke arm receiving portion 589, the first yoke arm 586 and/or the second yoke arm 588 may be hydro-formed and therefore may form a portion of the hydro-formed portion 597 of the first tube yoke member 542. According to the embodiment illustrated in FIGS. 8 and 9 and as a non-limiting example, the hydro- formed portion 597 proximate the of the first and second yoke arms 586 and 588 may be disposed at lengths Ll and L4 from an end of the substantially tubular portion 585 of the first tube yoke member 542, opposite the hydro-formed portion 597. Additionally, in accordance with the embodiment illustrated in FIGS. 8 and 9 and as a non-limiting example, the hydro-formed portion 597 proximate the first protruding portion 502, the second protruding portion 524, the first yoke arm receiving portion 587 and the second yoke arm receiving portion 589 may be disposed at lengths L7 and L10 from the end of the substantially tubular portion 585 of the first tube yoke member 542, opposite the hydro-formed portion 597. This minimizes the overall amount of material that is deformed by the hydro-forming process in order to form the first tube yoke member 542 thereby improving the overall structural rigidity of the of the first tube yoke member 542. It is therefore to be understood that the shape and geometry of the hydro- formed portion 597 is critical in ensuring that the first tube yoke member 542 is capable of withstanding the forces exerted thereon when in operation.

It is within the scope of this disclosure and as a non-limiting example that at least a portion of the substantially tubular portion 595 of the first tube yoke member 542 may form a portion of a shaft or may be utilized in order to connect at least a portion of the first tube yoke member 542 to a shaft. As a non-limiting example, the shaft may be a drive shaft, a propeller shaft, a driven shaft, a prop shaft, a cardan shaft or a double cardan shaft.

In accordance with the embodiment illustrated in FIG. 13 and as a non-limiting example, the second tube yoke member 544 may include a first yoke arm receiving portion 591 and a second yoke arm receiving portion 593. The first and second yoke arm receiving portions 591 and 593 may be of a size and shape to receive at least a portion of the first and second yoke arms 586 and 588 of the first tube yoke member 542. As best seen in FIG. 13 and as a non-limiting example, the first and second yoke arm receiving portions 591 and 593 may extend inward into the second tube yoke member 544 toward the first end portion 598 of the second tube yoke member 544. As a non-limiting example, at least a portion of the second and fourth protruding portions 516 and 538 of the second tube yoke member 544 may be disposed proximate to an end of the first and second yoke arm receiving portions 591 and 593, opposite an outermost end of the first and second yoke arms 590 and 592 of the second tube yoke member 544. By locating the second and fourth protruding portions 516 and 538 in this location, it aids in ensuring that the first and second yoke arms 590 and 592 of the second tube yoke member 544 have the structural rigidity needed in order to resist deformation when in operation. It is therefore to be understood that the location of the second and fourth protruding portions 516 and 538 are critical to ensuring that the first and second yoke arms 590 and 592 of the second tube yoke member 544 are capable of

withstanding the exerted thereon when in operation.

As a result, it is therefore to be understood that the second tube yoke member 544 includes a substantially tubular portion 599 and a hydro-formed portion 601. It is within the scope of this disclosure and as a non-limiting example that the second protruding portion 516, the fourth protruding portion 538, the first yoke arm receiving portion 591, the second yoke arm receiving portion 593, the first yoke arm 590 and/or the second yoke arm 592 may be hydro-formed and therefore may form a portion of the hydro-formed portion 601 of the second tube yoke member 544. According to the embodiment illustrated in FIGS. 8 and 9 and as a non-limiting example, the hydro- formed portion 601 proximate the of the first and second yoke arms 590 and 592 may be disposed at lengths L2 and L5 from an end of the substantially tubular portion 599 of the second tube yoke member 544, opposite the hydro-formed portion 601.

Additionally, in accordance with the embodiment illustrated in FIGS. 8 and 9 and as a non-limiting example, the hydro-formed portion 601 proximate the second protruding portion 516, the fourth protruding portion 538, the first yoke arm receiving portion 591 and the second yoke arm receiving portion 593 may be disposed at lengths L8 and LI 1 from the end of the substantially tubular portion 599 of the second tube yoke member 544, opposite the hydro-formed portion 601. This minimizes the overall amount of material that is deformed by the hydro-forming process in order to form the second tube yoke member 544 thereby improving the overall structural rigidity of the of the second tube yoke member 544. It is therefore to be understood that the shape and geometry of the hydro-formed portion 601 is critical in ensuring that the second tube yoke member 544 is capable of withstanding the forces exerted thereon when in operation.

It is within the scope of this disclosure and as a non-limiting example that at least a portion of the substantially tubular portion 599 of the second tube yoke member 544 may form a portion of a shaft or may be utilized in order to connect at least a portion of the second tube yoke member 544 to a shaft. As a non-limiting example, the shaft may be a drive shaft, a propeller shaft, a driven shaft, a prop shaft, a cardan shaft or a double cardan shaft.

In referencing FIGS. 4 and 13 of the disclosure, once the first tube yoke member 542 and the second tube yoke member 544 have been separated 546 from the hydro-formed member 434, a first yoke arm opening 604 and a second yoke arm opening 606 are formed 608 in the first and second yoke arms 586 and 588 of the first tube yoke member 542. As best seen in FIG. 13 of the disclosure and as a non-limiting example, the first yoke arm opening 604 in the first yoke arm 586 of the first tube yoke member 542 has a surface 605 defining the first yoke arm opening 604 and the second yoke arm opening 606 in the second yoke arm 588 of the first tube yoke member 542 has a surface 618 defining the second yoke arm opening 606. Additionally, as best seen in FIG. 13 of the disclosure, the first and second yoke arm openings 604 and 606 of the first tube yoke member 542 may be formed in the substantially flat portions 472 and 490 of the first and second yoke arms 586 and 588 of the first tube yoke member 542. By forming the first and second yoke arm openings 604 and 606 in the substantially flat portions 472 and 490 of the first tube yoke member 542, it aids in ensuring that the first and second yoke arm openings 604 and 606 are properly formed and aligned with each other. In the event that the first and second yoke arm openings 604 and 606 are not aligned, it reduces the overall life and durability of the first tube yoke member 542. As a result, it is to be understood that forming the first and second yoke arm openings 604 and 606 in the substantially flat portions 472 and 490 of the first tube yoke member 542 is critical in providing a hydro-formed first tube yoke member 542 that is capable of withstanding the forces exerted onto the first tube yoke member 542 when in operation. It is within the scope of this disclosure and as a non-limiting example that the first and second yoke arm openings 604 and 606 of the first tube yoke member 542 may be formed by using one or more flow drilling processes, one or more laser cutting processes, one or more water jet cutting processes, one or more machining processes and/or one or more drilling processes.

As best seen in FIG. 13 of the disclosure and as a non-limiting example, the first and second yoke arm openings 604 and 606 of the first tube yoke member 542 are aligned with one another. It is within the scope of this disclosure that the first and second yoke arm openings 604 and 606 of the first tube yoke member 542 have a size and shape to receive and/or retain at least a portion of a trunnion (not shown) of a plurality of trunnions (not shown) extending from a body portion of a journal cross (not shown). Additionally, it is within the scope of this disclosure that the first and second yoke arm openings 604 and 606 of the first tube yoke member 542 may have a size and shape to receive and/or retain at least a portion of a bearing cap assembly (not shown) on the outer surface of the plurality of trunnions (not shown) extending from the body portion of the journal cross (not shown).

According to the embodiment of the disclosure where the first and second yoke arm openings 604 and 606 of the first tube yoke member 542 are formed using one or more flow drilling processes, it creates a radially outboard extending portion 610 on the outer surface 578 of the first yoke arm 586. Additionally, the flow-drilling process creates a radially inward extending portion 612 on the inner surface 576 of the first yoke arm 586 of the first tube yoke member 542. It is within the scope of this disclosure and as a non-limiting example that the radially outward extending portion 610 of the first yoke arm opening 604 may have a length that is less than a length of the radially inward extending portion 612 of the first yoke arm opening 604 in the first yoke arm 586 of the first tube yoke member 542. By creating a first yoke arm opening 604 with radially outward 610 and radially inward extending portions 612, it provides an increased amount of surface area for the surface 605 defining the first yoke arm opening 604 in the first yoke arm 586 of the first tube yoke member 542. This increase in surface area for the surface 605 aids in increasing the structural rigidity of the first tube yoke member 542. Additionally, the increased surface area for the surface 605 of the first yoke arm opening 604 provides the first yoke arm opening 604 and the first yoke arm 586 with the additional material thickness needed to resist deformation when in operation. As a result, the radially outward 610 and radially inward extending portions 612 of the first yoke arm opening 604 of the first yoke arm 586 of the first tube yoke member 542 aids in increasing the overall life and durability of the first tube yoke member 542.

As best seen in FIG. 13 of the disclosure and as a non-limiting example, the second yoke arm opening 606 of the second yoke arm 588 of the first tube yoke member 542 includes a radially outward extending portion 614 and a radially inward extending portion 616 that is created by the one or more flow drilling processes. It is within the scope of this disclosure and as a non-limiting example that the radially outward extending portion 614 of the second yoke arm opening 606 may have a length that is less than a length of the radially inward extending portion 616 of the second yoke arm 588. By creating a second yoke arm opening 606 with radially outward 614 and radially inward extending portions 616, it provides an increased amount of surface area for the surface 618 defining the second yoke arm opening 606 in the second yoke arm 588 of the first tube yoke member 542. This increase in surface area for the surface 618 aids in increasing the structural rigidity of the first tube yoke member 542.

Additionally, the increased surface area for the surface 618 of the second yoke arm opening 606 provides the second yoke arm opening 606 and the second yoke arm 588 with the additional material thickness needed to resist deformation when in operation. As a result, the radially outward 614 and radially inward extending portions 616 of the second yoke arm opening 606 of the second yoke arm 588 of the first tube yoke member 542 aids in increasing the overall life and durability of the first tube yoke member 542.

In referencing FIGS. 4 and 13 of the disclosure, once the second tube yoke member 542 and the second tube yoke member 544 have been separated 546 from the hydro-formed member 434, a first yoke arm opening 620 and a second yoke arm opening 622 are formed 624 in the first and second yoke arms 590 and 592 of the second tube yoke member 544. As best seen in FIG. 13 of the disclosure, the first yoke arm opening 620 in the first yoke arm 590 of the second tube yoke member 544 has a surface 626 defining the first yoke arm opening 620 and the second yoke arm opening 622 in the second yoke arm 592 of the second tube yoke member 544 has a surface 628 defining the second yoke arm opening 622. Additionally, as best seen in FIG. 13 of the disclosure, the first and second yoke arm openings 620 and 622 of the second tube yoke member 544 are formed in the substantially flat portions 472 and 490 of the first and second yoke arms 590 and 592 of the second tube yoke member 544. By forming the first and second yoke arm openings 620 and 622 in the substantially flat portions 472 and 490 of the second tube yoke member 544, it aids in ensuring that the first and second yoke arm openings 620 and 622 are properly formed and aligned with each other. In the event that the first and second yoke arm openings 620 and 622 are not aligned, it reduces the overall life and durability of the second tube yoke member 544. As a result, it is to be understood that forming the first and second yoke arm openings 620 and 622 in the substantially flat portions 472 and 490 of the second tube yoke member 544 is critical in providing a hydro-formed second tube yoke member 544 that is capable of withstanding the forces exerted onto the second tube yoke member 544 when in operation. It is within the scope of this disclosure and as a non-limiting example, that the first and second yoke arm openings 620 and 622 of the second tube yoke member 544 may be formed by using one or more flow drilling processes, one or more laser cutting processes, one or more water jet cutting processes, one or more machining processes and/or one or more drilling processes.

As best seen in FIG. 13 of the disclosure and as a non-limiting example, the first and second yoke arm openings 620 and 622 of the second tube yoke member 544 are aligned with one another. It is within the scope of this disclosure that the first and second yoke arm openings 620 and 622 of the second tube yoke member 544 have a size and shape to receive and/or retain at least a portion of a trunnion (not shown) of the plurality of trunnions (not shown) extending from the body portion of the journal cross (not shown). Additionally, it is within the scope of this disclosure that the first and second yoke arm openings 620 and 622 of the second tube yoke member 544 may have a size and shape to receive and/or retain at least a portion of a bearing cap assembly (not shown) on the outer surface of the plurality of trunnions (not shown) extending from the body portion of the journal cross (not shown).

According to the embodiment of the disclosure where the first and second yoke arm openings 620 and 622 of the second tube yoke member 544 are formed using one or more flow drilling processes, it creates a radially outboard extending portion 630 on the outer surface 596 of the first yoke arm 590. Additionally, the flow-drilling process creates a radially inward extending portion 632 on the inner surface 594 of the first yoke arm 590 of the second tube yoke member 544. It is within the scope of this disclosure and as a non-limiting example that the radially outward extending portion 630 of the first yoke arm opening 620 may have a length that is less than a length of the radially inward extending portion 632 of the first yoke arm opening 620 in the first yoke arm 590 of the second tube yoke member 544. By creating a first yoke arm opening 620 with radially outward 630 and radially inward extending portions 632, it provides an increased amount of surface area for the surface 626 defining the first yoke arm opening 620 in the first yoke arm 590 of the second tube yoke member 544. This increase in surface area for the surface 626 aids in increasing the structural rigidity of the second tube yoke member 544. Additionally, the increased surface area for the surface 626 of the first yoke arm opening 620 provides the first yoke arm opening 620 and the first yoke arm 590 with the additional material thickness needed to resist deformation when in operation. As a result, the radially outward 630 and radially inward extending portions 632 of the first yoke arm opening 620 of the first yoke arm 590 of the second tube yoke member 544 aids in increasing the overall life and durability of the second tube yoke member 544.

As best seen in FIG. 13 of the disclosure and as a non-limiting example, the second yoke arm opening 622 of the second yoke arm 592 of the second tube yoke member 544 includes a radially outward extending portion 634 and a radially inward extending portion 636 that is created by the one or more flow drilling processes. It is within the scope of this disclosure and as a non-limiting example that the radially outward extending portion 634 of the second yoke arm opening 622 may have a length that is less than a length of the radially inward extending portion 636 of the second yoke arm 592. By creating a second yoke arm opening 622 with radially outward 634 and radially inward extending portions 636, it provides an increased amount of surface area for the surface 628 defining the second yoke arm opening 622 in the second yoke arm 592 of the second tube yoke member 544. This increase in surface area for the surface 628 aids in increasing the structural rigidity of the second tube yoke member 544. Additionally, the increased surface area for the surface 628 of the second yoke arm opening 622 provides the second yoke arm opening 622 and the second yoke arm 592 with the additional material thickness needed to resist deformation when in operation. As a result, the radially outward 634 and radially inward extending portions 636 of the second yoke arm opening 622 of the second yoke arm 592 of the second tube yoke member 544 aids in increasing the overall life and durability of the second tube yoke member 544. Once the first and second yoke arm openings 604 and 606 of the first tube yoke member 542 have been formed 608, a first shaft 638 is attached 640 to at a portion of the first end portion 580 of the first tube yoke member 542. ft is within the scope of this disclosure and as a non-limiting example that the first shaft 638 may be attached 640 to the first end portion 580 of the first tube yoke member 542 by using one or more welds, one or more mechanical fasteners, one or more adhesives, a splined connection and/or a threaded connection. As a non-limiting example, the first shaft 638 maybe a drive shaft, a propeller shaft, a driven shaft, a prop shaft, a cardan shaft or a double cardan shaft.

After the first and second yoke arm openings 620 and 622 of the second tube yoke member 544 have been formed 624, a second shaft 642 is attached 644 to at a portion of the first end portion 598 of the second tube yoke member 544. It is within the scope of this disclosure and as a non-limiting example that the second shaft 642 may be attached 644 to the first end portion 598 of the second tube yoke member 544 by using one or more welds, one or more mechanical fasteners, one or more adhesives, a splined connection and/or a threaded connection. As a non-limiting example, the second shaft 642 may be a drive shaft, a propeller shaft, a driven shaft, a prop shaft, a cardan shaft or a double cardan shaft.

In light of the above-disclosure, it is to be understood that the geometry and the hydro-forming process used to create the first and second tube yoke members 542 and 544, the first and second members 542 and 544 are able to have the stiffness needed to resist deformation and failure when in operation while having a reduced material thickness and weight. By reducing the overall weight of the first and second tube yoke members 542 and 544, the overall amount of weight of the drive-line of the vehicle can be reduced thereby aiding in increasing the overall fuel efficiency of the vehicle. As a result, the hydro-formed members 542 and 544 described herein are stronger, lighter and more cost efficient than the conventional tube yoke members.

It is within the scope of the disclosure that the first and second tube yoke members 542 and 544 may be used in combination with a coupling assembly (not shown). As a non-limiting example, the coupling assembly (not shown) having the first and second tube yoke members 542 and 544 may be a universal joint assembly, U-joint assembly, a universal coupling assembly, a Cardan joint, a Spicer joint, a Hardy Spicer joint or a Hook’s joint. FIG. 14 is a schematic perspective view of a first tube yoke member 700 and a second tube yoke member 702 according to an alternative embodiment of the disclosure. The first and second tube yoke members 700 and 702 illustrated in FIG. 14 are the same as the first and second tube yoke members 542 and 544 illustrated in FIGS. 8-13, except where specifically noted below. It is within the scope of this disclosure and as a non-limiting example that the first and second tube yoke members 700 and 702 may be formed in accordance with the hydro-forming method previously described.

As illustrated in FIG. 14 of the disclosure and as a non-limiting example, the first tube yoke member 700 further includes a first axially extending portion 704 that is interposed between the convex portion 520 and the second concave portion 522 of the first side 460 of the first tube yoke member 700. Additionally, as illustrated in FIG. 14 of the disclosure and as a non-limiting example, the first tube yoke member 700 further includes a second axially extending portion 706. The second axially extending portion 706 of the first tube yoke member 700 is interposed between the convex portion 520 and the second concave portion 522 of the second side 462 of the first tube yoke member 700. As a non-limiting example, the first and second axially extending portions 704 and 706 of the first tube yoke member 700 may be interposed between the first and third protruding portions 502 and 524 and the first and second yoke arm receiving portions 587 and 589 of the first tube yoke member 700. As a result, it is therefore to be understood that the first and second axially extending portions 704 and 710 of the first tube yoke member 700 may be hydro-formed and form at least a portion of the hydro- formed portion 597 of the first tube yoke member 700.

It is to be understood that the first and second axially extending portions 704 and 706 of the first tube yoke member 700 in combination with the first and third protruding portions 502 and 524 aid in providing structural support for the first tube yoke member 700 by increasing the structural rigidity of the first tube yoke member 700. By increasing the structural rigidity of the first tube yoke member 700, the first tube yoke member 700 is able to experience a wider array of forces in operation without failing. Furthermore, it is to be understood that the first and third protruding portions 502 and 524 and the first and second axially extending portions 704 and 706 of the first tube yoke member 700 aid in providing the first and second yoke arms 586 and 588 with the structural support needed to resist deformation when in operation. Therefore, the first and third protruding portions 502 and 524 in combination with the first and second axially extending portions 704 and 706 of the first tube yoke member 700 aid in increasing the overall life and durability of the first tube yoke member 700.

In accordance with the embodiment of the disclosure illustrated in FIG. 14 and as a non-limiting example, the second tube yoke member 702 may further include a first axially extending portion 708 that is interposed between the convex portion 512 and the second concave portion 514 of the first side 460 of the second tube yoke member 702. Additionally, as illustrated in FIG. 14 of the disclosure and as a non- limiting example, the second tube yoke member 702 may further include a second axially extending portion 710. The second axially extending portion 710 of the second tube yoke member 702 may be interposed between the convex portion 534 and the second concave portion 536 of the second side 462 of the second tube yoke member 702. As a non-limiting example, the first and second axially extending portions 708 and 710 of the second tube yoke member 702 may be interposed between the second and fourth protruding portions 516 and 538 and the first and second yoke arm receiving portions 591 and 593 of the second tube yoke member 702. As a result, it is therefore to be understood that the first and second axially extending portions 708 and 710 of the second tube yoke member 702 may be hydro-formed and form at least a portion of the hydro-formed portion 601 of the second tube yoke member 702.

It is to be understood that the first and second axially extending portions 708 and 710 of the second tube yoke member 702 in combination with the second and fourth protruding portions 516 and 538 aid in providing structural support for the second tube yoke member 702 by increasing the structural rigidity of the second tube yoke member 702. By increasing the structural rigidity of the second tube yoke member 702, the second tube yoke member 702 is able to experience a wider array of forces in operation without failing. Furthermore, it is to be understood that the second and fourth protruding portions 516 and 538 and the first and second axially extending portions 708 and 710 of the second tube yoke member 702 aid in providing the first and second yoke arms 590 and 592 with the structural support needed to resist deformation when in operation. Therefore, the second and fourth protruding portions 516 and 538 in combination with the first and second axially extending portions 708 and 710 of the second tube yoke member 702 aid in increasing the overall life and durability of the second tube yoke member 702. At least a portion of an end of the first shaft 638 is connected to at least a portion of a first end portion 712 of the first tube yoke member 700. It is within the scope of this disclosure and as a non-limiting example that the end of the first shaft 638 may be connected to at least a portion of the first end portion 712 of the first tube yoke member 700 by using one or more mechanical fasteners, one or more welds, one or more adhesives, a splines connection and/or a threaded connection.

As illustrated in FIG. 14 of the disclosure and as a non-limiting example, at least a portion of an end of the second shaft 642 is connected to at least a portion of a first end portion 714 of the second tube yoke member 702. It is within the scope of this disclosure and as a non-limiting example that the end of the second shaft 642 may be connected to the first end portion 714 of the second tube shaft 702 by using one or more mechanical fasteners, one or more welds, one or more adhesives, a splined connection and/or a threaded connection.

In light of the above-disclosure, it is to be understood that the geometry and the hydro-forming process used to create the first and second tube yoke members 700 and 702, the first and second members 700 and 702 are able to have the stiffness needed to resist deformation and failure when in operation while having a reduced material thickness and weight. By reducing the overall weight of the first and second tube yoke members 700 and 702, the overall amount of weight of the drive-line of the vehicle can be reduced thereby aiding in increasing the overall fuel efficiency of the vehicle. As a result, the hydro-formed members 700 and 702 described herein are stronger, lighter and more cost efficient than the conventional tube yoke members.

It is within the scope of the disclosure that the first and second tube yoke members 700 and 702 may be used in combination with a coupling assembly (not shown). As a non-limiting example, the coupling assembly (not shown) having the first and second tube yoke members 700 and 702 may be a universal joint assembly, U-joint assembly, a universal coupling assembly, a Cardan joint, a Spicer joint, a Hardy Spicer j oint or a Hook’ s j oint.

FIG. 15 is a schematic perspective view of a first tube yoke member 800 and a second tube yoke member 802 according to another embodiment of the disclosure. The first and second tube yoke members 800 and 802 illustrated in FIG. 15 are the same as the first and second tube yoke members 542, 700, 544 and 702 illustrated in FIGS. 8- 14, except where specifically noted below. It is within the scope of this disclosure and as a non-limiting example that the first and second tube yoke members 800 and 802 may be formed in accordance with the hydro-forming method previously described.

As illustrated in FIG. 15 of the disclosure and as a non-limiting example, the first tube yoke member 800 has a first end portion 804, a second end portion 806 and an intermediate portion 808 interposed between the first and second end portions 804 and 806 of the first tube yoke member 800. Extending outward from at least a portion of the intermediate portion 808 of the first tube yoke member 800 is a frustum portion 810. According to an embodiment of the disclosure and as a non-limiting example, the frustum portion 810 of the first tube yoke member 800 is substantially conical in shape. In accordance with an alternative embodiment of the disclosure and as a non-limiting example, the frustum portion 810 of the first tube yoke member 800 may be

substantially polygonal in shape having one or more substantially flat portions 812. It is within the scope of this disclosure and as a non-limiting example that the one or more substantially flat portions 812 of the frustum portion 810 may be aligned with the substantially flat portions 472 and/or 490 of the first tube yoke member 800.

It is to be understood that the frustum portion 810 of the first tube yoke member 800 aids in providing structural support for the first tube yoke member 800 by increasing the overall structural rigidity of the first tube yoke member 800. By increasing the structural rigidity of the first tube yoke member 800, the first tube yoke member 800 is able to experience a wider array of forces when in operation without failing. Furthermore, it is to be understood that the frustum portion 810 of the first tube yoke member 800 aids in providing the first and second yoke arms 586 and 588 with the structural support needed to resist deformation when in operation. Therefore, the frustum portion 810 of the first tube yoke member 800 aids in increasing the overall life and durability of the first tube yoke member 800 and is critical in providing a hydro- formed first tube yoke member 800 that is capable of withstanding the forces exerted onto the first tube yoke member 800 when in operation.

Disposed at an end of the frustum portion 810 of the first tube yoke member 800, opposite the first substantially cylindrical portion 450 of the first tube yoke member 800, is a convex portion 814. The convex portion 814 of the first tube yoke member 800 extends outward from the end of the frustum portion 810 opposite the first substantially cylindrical portion 450. As illustrated in FIG. 15 of the disclosure, at least a portion of an end of the convex portion 814, opposite the frustum portion 810 of the first tube yoke member 800, transitions into the first substantially convex portions 470 and 486 of the top portion 456, the second substantially convex portions 474 and 488 of the bottom portion 458, the convex portions 512 and 520 of the first and second sides 460 and 462 of the first tube yoke member 800.

At least a portion of an end of the first shaft 638 is connected to at least a portion of a first end portion 804 of the first tube yoke member 800. It is within the scope of this disclosure and as a non-limiting example that the end of the first shaft 638 may be connected to at least a portion of the first end portion 804 of the first tube yoke member 800 by using one or more mechanical fasteners, one or more welds, one or more adhesives, a splines connection and/or a threaded connection.

As illustrated in FIG. 15 of the disclosure and as a non-limiting example, the second tube yoke member 802 has a first end portion 816, a second end portion 818 and an intermediate portion 820 interposed between the first and second end portions 816 and 818 of the second tube yoke member 802. Extending outward from at least a portion of the intermediate portion 820 of the second tube yoke member 802 is a frustum portion 822. According to an embodiment of the disclosure and as a non- limiting example, the frustum portion 822 of the second tube yoke member 802 is substantially conical in shape. In accordance with an alternative embodiment of the disclosure and as a non-limiting example, the frustum portion 822 of the second tube yoke member 802 may be substantially polygonal in shape having one or more substantially flat portions 824. It is within the scope of this disclosure and as a nonlimiting example that the one or more substantially flat portions 824 of the frustum portion 822 may be aligned with the substantially flat portions 472 and/or 490 of the second tube yoke member 802.

It is to be understood that the frustum portion 822 of the second tube yoke member 802 aids in providing structural support for the second tube yoke member 802 by increasing the overall structural rigidity of the second tube yoke member 802. By increasing the structural rigidity of the second tube yoke member 802, the second tube yoke member 802 is able to experience a wider array of forces when in operation without failing. Furthermore, it is to be understood that the frustum portion 822 of the second tube yoke member 802 aids in providing the first and second yoke arms 590 and 592 with the structural support needed to resist deformation when in operation.

Therefore, the frustum portion 822 of the second tube yoke member 802 aids in increasing the overall life and durability of the second tube yoke member 802 and is critical in providing a hydro-formed second tube yoke member 802 that is capable of withstanding the forces exerted onto the second tube yoke member 802 when in operation.

Disposed at an end of the frustum portion 822 of the second tube yoke member 802, opposite the second substantially cylindrical portion 452 of the second tube yoke member 802, is a convex portion 826. The convex portion 826 of the second tube yoke member 802 extends outward from the end of the frustum portion 822 opposite the second substantially cylindrical portion 452. As illustrated in FIG. 15 of the disclosure, at least a portion of an end of the convex portion 826, opposite the frustum portion 822 of the second tube yoke member 802, transitions into the first substantially convex portions 470 and 486 of the top portion 456, the second substantially convex portions 474 and 488 of the bottom portion 458, the convex portions 512 and 520 of the first and second sides 460 and 462 of the second tube yoke member 802.

At least a portion of an end of the second shaft 642 is connected to at least a portion of a first end portion 816 of the second tube yoke member 802. It is within the scope of this disclosure and as a non-limiting example that the end of the second shaft 642 may be connected to at least a portion of the first end portion 816 of the second tube yoke member 802 by using one or more mechanical fasteners, one or more welds, one or more adhesives, a splines connection and/or a threaded connection.

In light of the above-disclosure, it is to be understood that the geometry and the hydro-forming process used to create the first and second tube yoke members 800 and 802, the first and second members 800 and 802 are able to have the stiffness needed to resist deformation and failure when in operation while having a reduced material thickness and weight. By reducing the overall weight of the first and second tube yoke members 800 and 802, the overall amount of weight of the drive-line of the vehicle can be reduced thereby aiding in increasing the overall fuel efficiency of the vehicle. As a result, the hydro-formed members 800 and 802 described herein are stronger, lighter and more cost efficient than the conventional tube yoke members.

It is within the scope of the disclosure that the first and second tube yoke members 800 and 802 may be used in combination with a coupling assembly (not shown). As a non-limiting example, the coupling assembly (not shown) having the first and second tube yoke members 800 and 802 may be a universal joint assembly, U-joint assembly, a universal coupling assembly, a Cardan joint, a Spicer joint, a Hardy Spicer joint or a Hook’s joint.

FIG. 16 is a schematic perspective view of a first tube yoke member 900 and a second tube yoke member 902 according to yet another embodiment of the disclosure. The first and second tube yoke members 900 and 902 illustrated in FIG. 16 are the same as the first and second tube yoke members 542, 700, 800, 544, 702 and 802 illustrated in FIGS. 8-15, except where specifically noted below. It is within the scope of this disclosure and as a non-limiting example that the first and second tube yoke members 900 and 902 may be formed in accordance with the hydro-forming method previously described.

As illustrated in FIG. 16 of the disclosure and as a non-limiting example, the first tube yoke member 900 may include one or more reinforcing portions 904 that are circumferentially disposed along at least a portion of the outer surface 578 of the first tube yoke member 900. According to an embodiment of the disclosure and as a non- limiting example, the one or more reinforcing portions 904 of the first tube yoke member 900 provide one or more recessed portions in the outer surface 578 of the first tube yoke member 900. In accordance with an alternative embodiment of the disclosure and as a non-limiting example, the one or more reinforcing portions 904 of the first tube yoke member 900 protrude from at least a portion of the outer surface 578 of the first tube yoke member 900 and may provide are area of increased material thickness. As a non-limiting example that the one or more reinforcing portions 904 of the first tube yoke member 900 are substantially egg-shaped, elliptical, ellipsoidal, oval, ovate and/or ovoid in shape.

It is within the scope of this disclosure and as a non-limiting example that the one or more reinforcing portions 904 of the first tube yoke member 900 may be disposed equidistant along the outer surface 578 of the first tube yoke member 900. According to the embodiment illustrated in FIG. 16 and as a non-limiting example, at least a portion of the one or more reinforcing portions 904 of the first tube yoke member 900 may be disposed on opposing sides of the first and/or second yoke arms 586 and/or 588 of the first tube yoke member 900. As a result, as best seen in FIG. 16 of the disclosure and as a non-limiting example, the one or more reinforcing portions 904 may be disposed within at least a portion of the frustum portion 810, the first yoke arm receiving portion 587, the second yoke arm receiving portion 589, the first yoke arm 586 and/or the second yoke arm 588 of the first tube yoke member 900.

At least a portion of an end of the first shaft 638 is connected to at least a portion of a first end portion 906 of the first tube yoke member 900. It is within the scope of this disclosure and as a non-limiting example that the end of the first shaft 638 may be connected to at least a portion of the first end portion 906 of the first tube yoke member 900 by using one or more mechanical fasteners, one or more welds, one or more adhesives, a splines connection and/or a threaded connection.

In accordance with the embodiment of the disclosure illustrated in FIG. 16 and as a non-limiting example, the second tube yoke member 902 may include one or more reinforcing portions 908 that are circumferentially disposed along at least a portion of the outer surface 596 of the second tube yoke member 902. According to an embodiment of the disclosure and as a non-limiting example, the one or more reinforcing portions 908 of the second tube yoke member 902 provide one or more recessed portions in the outer surface 596 of the second tube yoke member 902. In accordance with an alternative embodiment of the disclosure and as a non-limiting example, the one or more reinforcing portions 908 of the second tube yoke member 902 protrudes from at least a portion of the outer surface 596 of the second tube yoke member 902 and may provide are area of increased material thickness. As a non- limiting example that the one or more reinforcing portions 908 of the second tube yoke member 902 are substantially egg-shaped, elliptical, ellipsoidal, oval, ovate and/or ovoid in shape.

It is within the scope of this disclosure and as a non-limiting example that the one or more reinforcing portions 908 of the second tube yoke member 902 may be disposed equidistant along the outer surface 596 of the second tube yoke member 902. According to the embodiment illustrated in FIG. 16 and as a non-limiting example, at least a portion of the one or more reinforcing portions 908 of the second tube yoke member 902 may be disposed on opposing sides of the first and/or second yoke arms 590 and/or 592 of the second tube yoke member 902. As a result, as best seen in FIG.

16 of the disclosure and as a non-limiting example, the one or more reinforcing portions 908 may be disposed within at least a portion of the frustum portion 822, the first yoke arm receiving portion 591, the second yoke arm receiving portion 593, the first yoke arm 590 and/or the second yoke arm 592 of the second tube yoke member 902.

At least a portion of an end of the second shaft 642 is connected to at least a portion of a first end portion 910 of the second tube yoke member 902. It is within the scope of this disclosure and as a non-limiting example that the end of the second shaft 642 may be connected to at least a portion of the first end portion 910 of the second tube yoke member 902 by using one or more mechanical fasteners, one or more welds, one or more adhesives, a splines connection and/or a threaded connection.

In light of the above-disclosure, it is to be understood that the geometry and the hydro-forming process used to create the first and second tube yoke members 900 and 902, the first and second members 900 and 902 are able to have the stiffness needed to resist deformation and failure when in operation, while still having an overall reduced weight and material thickness. By reducing the overall weight of the first and second tube yoke members 900 and 902, the overall amount of weight of the drive-line of the vehicle can be reduced thereby aiding in increasing the overall fuel efficiency of the vehicle. As a result, the hydro-formed members 900 and 902 described herein are stronger, lighter and more cost efficient than the conventional tube yoke members.

It is within the scope of the disclosure that the first and second tube yoke members 900 and 902 may be used in combination with a coupling assembly (not shown). As a non-limiting example, the coupling assembly (not shown) having the first and second tube yoke members 900 and 902 may be a universal joint assembly, U-joint assembly, a universal coupling assembly, a Cardan joint, a Spicer joint, a Hardy Spicer joint or a Hook’s joint.

It is within the scope of this disclosure that the various embodiments of the disclosure described and illustrated herein may be combined with one another to make a hydro-formed tube yoke member according to an embodiment of the disclosure.

In accordance with the provisions of the patent statutes, the present invention has been described to represent what is considered to represent the preferred embodiments. However, it should be note that this invention can be practiced in other ways than those specifically illustrated and described without departing from the spirit or scope of this invention.

Claims

What is claimed is:

1. A method of forming a tube yoke member, comprising the steps of: providing a tube blank having a first end portion and a second end portion; providing a mould with one or more inner surfaces having a pre-determined shape;

inserting at least a portion of said tube blank into said mould provided;

attaching a first actuator assembly to at least a portion of said first end portion of said tube blank;

attaching a second actuator assembly to at least a portion of said second end portion of said tube blank;

hydro-forming said tube blank into a hydro-formed member with a pre- determined shape complementary to said one or more inner surfaces of said mould; applying an amount of force onto said first end portion and said second end portion of said tube blank by said first and second actuator assemblies;

separating a first tube yoke member and a second tube yoke member from said hydro-formed member, wherein said first tube yoke member and said second tube yoke member have a substantially tubular portion and a hydro-formed portion;

forming a first yoke arm opening and a second yoke arm opening in a first yoke arm and a second yoke arm of said first tube yoke member; and

forming a first yoke arm opening and a second yoke arm opening in a first yoke arm and a second yoke arm of said second tube yoke member.

2. The method of claim 1, wherein said first tube yoke member and said tube yoke member are separated from said hydro-formed member by using one or more plasma cutting processes, one or more laser cutting processes and/or one or more water jet cutting processes.

3. The method according to any one of the previous claims, wherein said first yoke are opening and said second yoke arm opening in said first and second yoke arms of said first tube yoke member are formed by using one or more flow drilling processes, one or more laser cutting processes, one or more water jet cutting processes, one or more machining processes and/or one or more drilling processes; and wherein said first yoke are opening and said second yoke arm opening in said first and second yoke arms of said second tube yoke member are formed by using one or more flow drilling processes, one or more laser cutting processes, one or more water jet cutting processes, one or more machining processes and/or one or more drilling processes.

4. The method according to any one of the previous claims, wherein said hydro-formed member has a first end portion, a second end portion, an intermediate portion, a top portion, a bottom portion, a first side and a second side;

wherein said first end portion of said top portion of said hydro-formed member has a concave portion which transitions into a convex portion;

wherein said intermediate portion of said top portion of said hydro-formed member has a first substantially convex portion and a second substantially convex portion disposed on opposing sides of a substantially flat portion;

wherein said second end portion of said top portion of said hydro-formed member has a concave portion which transitions into a convex portion;

wherein said first end portion of said bottom portion of said hydro-formed member has a concave portion which transitions into a convex portion;

wherein said intermediate portion of said bottom portion of said hydro-formed member has a first substantially convex portion and a second substantially convex portion disposed on opposing sides of a substantially flat portion;

wherein said second end portion of said bottom portion of said hydro-formed member has a concave portion which transitions into a convex portion;

wherein said first end portion of said first side of said hydro-formed member has a convex portion interposed between a first concave portion and a second concave portion;

wherein said intermediate portion of said first side of said hydro-formed member has a first convex portion and a second convex portion disposed on opposing sides of a substantially flat portion;

wherein said second end portion of said first side of said hydro-formed member has a convex portion interposed between a first concave portion and a second concave portion; wherein said first end portion of said second side of said hydro-formed member has a convex portion interposed between a first concave portion and a second concave portion;

wherein said intermediate portion of said second side of said hydro-formed member has a first convex portion and a second convex portion disposed on opposing sides of a substantially flat portion; and

wherein said second end portion of said second side of said hydro-formed member has a convex portion interposed between a first concave portion and a second concave portion.

5. The method according to any one of the previous claims, wherein said concave portion of said first end portion of said top portion of said hydro-formed member is disposed a length Ll from a first end of said hydro-formed member;

wherein said concave portion of said second end portion of said top portion of said hydro-formed member is disposed a length L2 from a second end of said hydro- formed member;

wherein said concave portion of said first end portion of said bottom portion of said hydro-formed member is disposed a length L4 from said first end of said hydro- formed member;

wherein said concave portion of said second end portion of said bottom portion of said hydro-formed member is disposed a length L5 from said second end of said hydro-formed member;

wherein said lengths Ll, L2, L4 and L5 are substantially equal to each other; wherein said first concave portion of said first end portion of said first side of said hydro-formed member is disposed a length L7 from said first end of said hydro- formed member;

wherein said first concave portion of said second end portion of said first side of said hydro-formed member is disposed a length L8 from said second end of said hydro- formed member;

wherein said first concave portion of said first end portion of said second side of said hydro-formed member is disposed a length L10 from said first end of said hydro- formed member; wherein said first concave portion of said second end portion of said second side of said hydro-formed member is disposed a length LI 1 from said second end of said hydro-formed member;

wherein said lengths L7, L8, L10 and Lll are substantially equal to each other; and

wherein said lengths Ll, L2, L4 and L5 are greater than said lengths L7, L8, L10 and Ll l.

6. The method according to any one of the previous claims, wherein said first tube yoke member is separated from said hydro-formed member by a first tube yoke member cut and said second tube yoke member is separated from said hydro- formed member by a second tube yoke member cut.

7. The method according to any one of the previous claims, wherein said first tube yoke member is separated from said hydro-formed member by a first tube yoke member cut and said second tube yoke member is separated from said hydro- formed member by a second tube yoke member cut;

wherein said first tube yoke member cut penetrates at least a portion of said first substantially convex portions, said substantially flat portions and said second substantially convex portions of said intermediate portions of said top and bottom portions of said hydro-formed member, said first convex portions, said second convex portions and said substantially flat portions of said intermediate portions of said first and second sides of said hydro-formed member, and said convex portions and said second concave portions of said first end portions of said first and second sides of said hydro-formed member; and

wherein said second tube yoke member cut penetrates at least a portion of said first substantially convex portions, said substantially flat portions and said second substantially convex portions of said intermediate portions of said top and bottom portions of said hydro-formed member, said first convex portions, said second convex portions and said substantially flat portions of said intermediate portions of said first and second sides of said hydro-formed member, and said convex portions and said second concave portions of said second end portions of said first and second sides of said hydro-formed member.

8. The method according to any one of the previous claims, wherein said hydro-formed portion of said first tube yoke member has a first protruding portion and a third protruding portion and wherein said hydro-formed portion of said second tube yoke member has a second protruding portion and fourth protruding portion.

9. The method according to any one of the previous claims, wherein at least a portion of said first protruding portion in said hydro-formed portion of said first tube yoke member is disposed in said convex portion of said first end portion of said second side, wherein at least a portion of said third protruding portion in said hydro- formed portion of said first tube yoke member is disposed in said convex portion of said first end portion of said first side, wherein at least a portion of said second protruding portion in said hydro-formed portion of said second tube yoke member is disposed in said convex portion of said second end portion of said second side, and wherein at least a portion of said fourth protruding portion in said hydro-formed portion of said second tube yoke member is disposed in said convex portion of said second end portion of said first side.

10. The method according to any one of the previous claims, wherein said first protruding portion in said hydro-formed portion of said first tube yoke member is disposed proximate to an end of a first yoke arm receiving portion in said hydro-formed portion of said first tube yoke member;

wherein said third protruding portion in said hydro-formed portion of said first tube yoke member is disposed proximate to an end of a second yoke arm receiving portion in said hydro-formed portion of said first tube yoke member;

wherein said second protruding portion in said hydro-formed portion of said second tube yoke member is disposed proximate to an end of a first yoke arm receiving portion in said hydro-formed portion of said second tube yoke member;

wherein said fourth protruding portion in said hydro-formed portion of said second tube yoke member is disposed proximate to an end of a second yoke arm receiving portion in said hydro-formed portion of said second tube yoke member.

11. The method according to any one of the previous claims, wherein said hydro-formed portion of said first tube yoke member has a first axially extending portion and a second axially extending portion, and wherein said hydro-formed portion of said second tube yoke member has a first axially extending portion and a second axially extending portion.

12. The method according to any one of the previous claims, wherein said hydro-formed portion of said first tube yoke member has a first axially extending portion and a second axially extending portion, and wherein said hydro-formed portion of said second tube yoke member has a first axially extending portion and a second axially extending portion;

wherein said first axially extending portion of said first tube yoke member is interposed between a first yoke arm receiving portion in said hydro-formed portion of said first tube yoke member and said first protruding portion of said first tube yoke member;

wherein said second axially extending portion of said first tube yoke member is interposed between a second yoke arm receiving portion in said hydro-formed portion of said first tube yoke member and said third protruding portion of said first tube yoke member;

wherein said first axially extending portion of said second tube yoke member is interposed between a first yoke arm receiving portion in said hydro-formed portion of said second tube yoke member and said first protruding portion of said second tube yoke member; and

wherein said second axially extending portion of said second tube yoke member is interposed between a first yoke arm receiving portion in said hydro-formed portion of said second tube yoke member and said first protruding portion of said second tube yoke member.

13. The method according to any one of the previous claims, wherein said hydro-formed portion of said first tube yoke member has a frustum portion and wherein said hydro-formed portion of said second tube yoke member has a frustum portion.

14. The method according to any one of the previous claims, wherein said frustum portion of said hydro-formed portion of said first tube yoke member has one or more substantially flat portions and wherein said frustum portion of said hydro-formed portion of said second tube yoke member has one or more substantially flat portions.

15. The method according to any one of the previous claims, wherein said hydro-formed portion of said first tube yoke member has one or more reinforcing portions and said hydro-formed portion of said second tube yoke member has one or more reinforcing portions.

16. The method according to any one of the previous claims, wherein said one or more reinforcing portions in said hydro-formed portion of said first tube yoke member are substantially egg-shaped, elliptical, ellipsoidal, oval, ovate and/or ovoid in shape and wherein said one or more reinforcing portions in said hydro-formed portion of said second tube yoke member are substantially egg-shaped, elliptical, ellipsoidal, oval, ovate and/or ovoid in shape.

17. The method according to any one of the previous claims, wherein said hydro-formed portion of said first tube yoke member has one or more reinforcing portions and said hydro-formed portion of said second tube yoke member has one or more reinforcing portions;

wherein at least a portion of said one or more reinforcing portions in said hydro- formed portion of said first tube yoke member are disposed within said frustum portion, said first yoke arm and/or said second yoke arm of said first yoke member; and

wherein at least a portion of said one or more reinforcing portions in said hydro- formed portion of said second tube yoke member are disposed within said frustum portion, said first yoke arm and/or said second yoke arm of said second yoke member.

18. The method according to any one of the previous claims, further comprising the steps of:

attaching at least a portion of a first fluid supply line to at least a portion of said first end portion of said tube blank; flowing an amount of fluid through said first fluid supply line into said tube blank to remove an amount of air from within said tube blank;

attaching at least a portion of a second fluid supply line to at least a portion of said second end portion of said tube blank after and/or while flowing an amount of fluid into said tube blank through said first fluid supply line; and

flowing an amount of fluid through said first and/or second fluid supply lines into said tube blank after attaching said second fluid supply line to said tube blank in order to remove all or substantially all of said air from within said tube blank.

19. A tube yoke member, comprising:

a substantially tubular portion;

a hydro-formed portion;

wherein said hydro-formed portion defines a first yoke arm, a second yoke arm, a first yoke arm receiving portion and a second yoke arm receiving portion; and

wherein said first yoke arm has a first yoke arm opening formed therein and said second yoke arm has a second yoke arm opening formed therein.

20. The tube yoke member of claim 19, wherein said hydro-formed portion of said tube yoke member has a first protruding portion and a third protruding portion preventing said first yoke arm and said second yoke arm from deforming;

wherein said first protruding portion is disposed proximate an end of said first yoke arm receiving portion opposite said first and second yoke arm openings; and wherein said third protruding portion is disposed proximate an end of said second yoke arm receiving portion opposite said first and second yoke arm openings.

21. The tube yoke member according to any one of the previous claims, wherein said hydro-formed portion of said tube yoke member proximate said first yoke arm is disposed a length LI from an end of said substantially tubular portion opposite said hydro-formed portion;

wherein said hydro-formed portion of said tube yoke member proximate said second yoke arm is disposed a length L4 from said end of said substantially tubular portion opposite said hydro-formed portion; wherein said length Ll and L4 are substantially equal to each other;

wherein said hydro-formed portion of said tube yoke member proximate said first protruding portion of said hydro-formed portion of said tube yoke member is disposed a length L7 from said end of said substantially tubular portion opposite said hydro-formed portion;

wherein said hydro-formed portion of said tube yoke member proximate said third protruding portion of said hydro-formed portion of said tube yoke member is disposed a length L10 from said end of said substantially tubular portion opposite said hydro-formed portion;

wherein said lengths L7 and L10 are substantially equal to each other; and wherein said lengths Ll and L4 are greater than said lengths L7 and L10.

22. The tube yoke member according to any one of the previous claims, wherein said hydro-formed portion of said tube yoke member further includes a first axially extending portion and a second axially extending portion;

wherein said first axially extending portion of said tube yoke member is interposed between said first yoke arm receiving portion in said hydro-formed portion of said tube yoke member and said first protruding portion of said tube yoke member; and

wherein said second axially extending portion of said tube yoke member is interposed between said second yoke arm receiving portion in said hydro-formed portion of said tube yoke member and said third protruding portion of said tube yoke member.

23. The tube yoke member according to any one of the previous claims, wherein said hydro-formed portion of said tube yoke member has a frustum portion.

24. The tube yoke member according to any one of the previous claims, wherein said frustum portion of said hydro-formed portion of said tube yoke member has one or more substantially flat portions.

25. The tube yoke member according to any one of the previous claims, wherein said hydro-formed portion of said tube yoke member has one or more reinforcing portions.

26. The tube yoke member according to any one of the previous claims, wherein said one or more reinforcing portions in said hydro-formed portion of said tube yoke member are substantially egg-shaped, elliptical, ellipsoidal, oval, ovate and/or ovoid in shape.

27. The tube yoke member according to any one of the previous claims, wherein at least a portion of said one or more reinforcing portions in said hydro-formed portion of said tube yoke member are disposed within said frustum portion, said first yoke arm and/or said second yoke arm of said yoke member.

28. The tube yoke member according to any one of the previous claims, wherein at least a portion of said one or more reinforcing portions in said hydro-formed portion of said tube yoke member are disposed on opposing sides of said first and/or second yoke arms of said tube yoke member.