Method for manufacturing a linear actuator

1. A method for manufacturing a linear actuator having a screw shaft with an externally threaded portion, the method comprising:

providing a thrust tube member for the linear actuator;

inserting a portion of the thrust tube member into a casting portion of a molding apparatus, the casting portion being fitted with a model screw member having a threaded portion that matches the externally threaded portion of the screw shaft, wherein the portion of the thrust tube inserted into the casting portion surrounds the threaded portion of the model screw member;

adding a molding material into the casting portion to overmold a nut onto the thrust tube member, the nut comprising a threaded portion on an internal circumference mateable with the threaded portion of the model screw member;

removing the thrust tube member from the casting portion of the molding apparatus into which the model screw member is fitted, wherein the thrust tube member is ready to receive the screw shaft of the linear actuator; and

coupling the overmolded nut and thrust tube member to a screw shaft of the actuator, wherein the threaded portion on the internal circumference of the nut mates with an externally threaded portion of the screw shaft and an outer portion of the nut is overmolded onto an external circumference of the thrust tube member.

2. The method of claim 1 , wherein the thrust member comprises a hollow tube.

3. The method of claim 1 , wherein the molding material comprises plastic.

4. The method of claim 1 , wherein the casting portion accommodates a variety of screw member sizes.

5. The method of claim 1 , wherein the casting portion accommodates a variety of screw member thread widths.

6. The method of claim 1 , further comprising machining a bearing journal onto an end of the screw shaft, the bearing journal adapted to interface with a motor for rotating the screw shaft.

7. The method of claim 1 , further comprising coupling a bearing journal assembly onto an end of the screw shaft, the bearing journal adapted to interface with a motor for rotating the screw shaft.

8. A method for manufacturing a linear actuator, the method comprising:

providing a screw shaft having an externally threaded portion and a first end;

fitting a model screw into a molding apparatus, the model screw having a threaded portion that matches the externally threaded portion of the screw shaft;

inserting a thrust tube into the molding apparatus, wherein a portion of the thrust tube surrounds the threaded portion of the model screw member;

overmolding a nut onto the thrust tube, the nut having an internally threaded portion on an internal circumference mateable with the threaded portion of the model screw member;

removing the thrust tube from the molding apparatus into which the model screw member is fitted;

mating the internally threaded portion of the plastic nut onto the externally threaded portion of the screw shaft, wherein an outer portion of the plastic nut is overmolded onto an external circumference of the thrust tube;

providing a bearing journal adapted to interface with a motor and having an end adapted to receive the first end of the screw shaft; and

coupling the bearing journal to the screw shaft by rotary swaging the end of the bearing journal onto the first end of the screw shaft.

9. A method of making a linear actuator, the method comprising:

providing a housing;

providing an elongated screw shaft having external threads, the elongated screw shaft being axially fixed and rotatable relative to the housing; and

coupling a thrust tube assembly to the elongated screw shaft, the thrust tube assembly comprising a thrust tube and a nut overmolded onto the thrust tube, the nut having an internally threaded portion on an internal circumference mateable with the external threads of the elongated screw shaft and an outer portion molded onto an external circumference of the thrust tube;

wherein the thrust tube assembly is manufactured by:

inserting the thrust tube into a casting portion of a molding apparatus, the casting portion being fitted with a model screw member having a threaded portion matching the external threads of the screw shaft, wherein a portion of the thrust tube surrounds the threaded portion of the model screw member;

adding a moldable material to said casting portion, thereby forming the nut and bonding the nut to said thrust tube; and

removing the thrust tube from the casting portion of the molding apparatus into which the model screw member is fitted, wherein the thrust tube assembly is ready to receive the elongated screw shaft.

10. The method of claim 9 , wherein the moldable material is plastic.

11. The method of claim 10 , wherein the casting portion accommodates a variety of screw member sizes.

12. The method of claim 10 , wherein the casting portion accommodates a variety of screw member thread widths.

13. A method of manufacturing a linear actuator, the method comprising:

providing a thrust tube member for the linear actuator;

providing a screw shaft for the linear actuator, the screw shaft having an externally threaded portion;

fitting a model screw member into a casting portion of a molding apparatus, the model screw member having a threaded portion that generally matches the externally threaded portion of the screw shaft;

inserting a portion of the thrust tube member into the casting portion of the molding apparatus, wherein the portion of the thrust tube member inserted into the casting portion surrounds the threaded portion of the model screw member;

adding a molding material into the casting portion to overmold a nut onto the thrust tube member, the nut comprising an internally threaded portion on an internal circumference mateable with the threaded portion of the model screw member;

removing the thrust tube member from the casting portion of the molding apparatus into which the model screw member is fitted, wherein the thrust tube member is ready to receive the screw shaft for the linear actuator; and

coupling the overmolded nut and thrust tube member onto the screw shaft, wherein the internally threaded portion of the nut mates with the externally threaded portion of the screw shaft and an outer portion of the nut is overmolded onto an external circumference of the thrust tube member.

14. The method of claim 13 , wherein the casting portion accommodates a variety of model screw members having varying thread widths selected for varying a linear velocity of the thrust tube assembly.

15. The method of claim 13 , further comprising providing a motor for driving the linear actuator.

16. The method of claim 15 , further comprising providing a housing for the motor and linear actuator, wherein the screw shaft is axially fixed with respect to the housing and rotatable by the motor relative to the housing.

17. The method of claim 16 , further comprising providing a bearing journal for the linear actuator, the bearing journal interfacing with the motor at a first end and with the screw shaft at a second end.

18. The method of claim 17 , wherein providing the bearing journal comprises machining the bearing journal directly onto an end of the screw shaft.