Shift lever vibration isolation assembly and methods of manufacture

Abstract

A shift lever assembly designed to isolate vibrations including an outer can having a bore and an outer wall, an inner can disposed within the bore, a vibration absorbing material positioned within the bore and around the inner can; and a sleeve extending from the outer wall of the outer can. The method of making the shift lever assembly includes positioning an outer can having a bore and an attached sleeve in a mold, positioning an inner can in the mold, within the bore of the outer can, injecting a vibration absorbing material into the mold, thereby filling the space within the bore of the outer can around the inner can, and allowing the vibration absorbing material to cure, thereby securing the inner can within the outer can.

What is claimed is: 
     
         1 . A method of producing a shift lever assembly comprising the steps of:
 positioning an outer can having a bore and a sleeve in a mold;   positioning an inner can in the mold, within the bore of the outer can and spaced from the outer can;   injecting a vibration absorbing material into the mold, thereby filling the space within the bore of the outer can around the inner can; and   allowing the vibration absorbing material to cure, thereby securing the inner can within the outer can.   
     
     
         2 . The method of  claim 1  further comprising the step of providing at least one stop between the inner can and the outer can before injecting a vibration absorbing material into the mold. 
     
     
         3 . The method of  claim 2  further comprising the step of providing a gap between the at least one stop between the inner can and the outer can and allowing the vibration absorbing material to flow through the gap when injected into the mold. 
     
     
         4 . The method of  claim 2  further comprising the step of press fitting the at least one stop between the inner can and the outer can. 
     
     
         5 . The method of  claim 2  further comprising the step of welding the at least one stop to the inner can before positioning the inner can in the bore of the outer can. 
     
     
         6 . The method of  claim 2  further comprising the step of welding the at least one stop to the outer can before positioning the inner can in the bore of the outer can. 
     
     
         7 . The method of  claim 1  wherein the inner can is positioned within the bore of the outer can so that at least one end of the inner can is not aligned with an end of the outer can. 
     
     
         8 . The method of  claim 1  further comprising the step of forming a chemical bond between the vibration absorbing material and the inner can and the outer can. 
     
     
         9 . The method of  claim 1  further comprising the step of mechanical entrapment of the inner can within the bore of the outer can by the vibration absorbing material. 
     
     
         10 . The method of  claim 1  further comprising the step of positioning multiple outer cans each having a bore and a sleeve in a mold; positioning an inner can in each of the outer can bores, and injecting a vibration absorbing material into the mold, thereby filling the spaces within the bore of each of the outer cans around the respective inner cans; and
 allowing the vibration absorbing material to cure, thereby securing each of the inner cans within the respective outer cans. 
 
     
     
         11 . The method of  claim 1  further comprising the step containing the vibration absorbing material substantially within the outer can by the mold. 
     
     
         12 . The method of  claim 1  further comprising the step of shaping the at least one stop to allow flow of the vibration absorbing material between the inner can and the outer can. 
     
     
         13 . The method of  claim 2  further comprising the step of providing two stops between the inner can and the outer can, with a first stop positioned proximate to a first end of the inner can and a second stop positioned proximate to a second end of the inner can. 
     
     
         14 . The method of  claim 2  further comprising the step of locating the at least one stop inwardly of an end of the outer can. 
     
     
         15 . The method of  claim 2  further comprising the step of forming the at least one stop and the inner can as one piece. 
     
     
         16 . The method of  claim 2  further comprising the step of forming the at least one stop and the outer can as one piece. 
     
     
         17 . The method of  claim 1  further comprising the step of forming the outer can with at least one end which is rolled over to entrap the vibration absorbing material. 
     
     
         18 . The method of  claim 1  further comprising the step of applying adhesive to the inner can prior to positioning the inner can in the mold within the bore of the outer can. 
     
     
         19 . The method of  claim 1  further comprising the step of applying adhesive to the outer can prior to positioning the outer can in the mold and prior to positioning the inner can within the bore of the outer can. 
     
     
         20 . A method of manufacturing a shift lever vibration isolation assembly, comprising the steps of:
 providing an outer can having a bore and an outer surface;   attaching a sleeve to the outer surface of the outer can;   providing a mold having at least one mold cavity for receiving the outer can and sleeve attached to the outer surface of the outer can;   positioning the outer can and sleeve attached to the outer surface of the outer can in the mold;   positioning an inner can within the bore of the outer can and spaced from an inner surface of the outer can, and   introducing a vibration absorbing material into the mold cavity and between the inner can and the inner surface of the outer can.   
     
     
         21 . The method of  claim 20  further comprising the step of providing at least one step between the inner can and the outer can before introducing the vibration absorbing material into the mold cavity and between the inner can and the inner surface of the outer can.