Automotive foot pedal and method of manufacture
A high strength and stiffness foot pedal includes a tubular metal core and an overmolded plastic component including a foot pad at one end of the pedal and a pivot lug at the other end.
1 . A foot pedal for use as an automotive brake or clutch operator, comprising:
an elongated lever body comprised of a metal tubular core;
a plastic overmolded component at least partially enclosing said metal tubular core, said plastic overmolded component including an integrally formed foot pad at one end of said elongated lever body and a pivot lug at the other end.
2 . The pedal according to claim 1 wherein said tubular core is constructed of steel.
3 . The pedal according to claim 1 wherein said overmolded component is molded from a glass filled plastic.
4 . The pedal according to claim 1 wherein said elongated lever body is curved.
5 . The pedal according to claim 3 wherein said plastic comprises nylon.
6 . A method of manufacturing an automotive brake pedal comprising the steps of:
forming an elongated lever body from a steel tubular core;
said step of forming an elongated lever body further including the step of overmolding a plastic component at least partially over said steel tubular core;
said step of overmolding said plastic component further including the step of molding a foot pad integral therewith at one end of said elongated lever body and a pivot lug at the other end thereof.
7 . The method according to claim 6 wherein a glass filled plastic is used to overmold said plastic component.
8 . The method according to claim 6 wherein said step of forming an elongated lever body further includes the step of forming said tubular core into a curved shape.