Method for producing a connection between flat materials and a correspondingly manufactured coupling and motor vehicle with such a coupling

Abstract

Method for producing a connection between flat materials (1, 2), comprising at least the following steps: a) Providing a first flat material (1) with at least one tab (3); b) Providing a second flat material (2) with at least one pocket (4), wherein an inner contour (5) of the at least one pocket (4) corresponds at least partially to an outer contour (6) of the at least one flap (3); c) Inserting at least one tab (3) of the first flat material (1) into at least one pocket (4) of the second flat material (2) so that the first flat material (1) and the second flat material (2) are interlocked; d) Forming the outer contour (6) of the at least one tab (3) or the inner contour (5) of the at least one pocket (4) in a forming area (7) such that the outer contour (6) of the at least one tab (3) and the inner contour (5) of the at least one pocket (4) overlap at least partially in the forming area (7) in the direction of a material plane (8); e) wherein the first and the second flat material (1, 2) are fixed perpendicular to the material plane (8).

Description

[0001] The present invention relates to a method for producing a connection between flat materials, which is used in particular for joining sheet metal components. Such sheet metal components are used, for example, in dampers for converters, clutches and similar components in the drive train of internal combustion engines.

[0002] Prior art methods for joining sheet metal components are known in which the components are stacked on top of each other and connected to one or more common holes using upsetting rivets in a form-fitting and play-free manner. A disadvantage of such riveted connections is that they require more installation space in the joining areas compared to the material thicknesses of the sheet metal components used. This increased space requirement results from the material thicknesses of the individual stacked components as well as the setting head and the closing head of the rivet.

[0003] Patent DE 10 2009 051 154 B4 discloses a method for manufacturing a sheet metal part, wherein at least two sheet metal components are formed, at least partially, with mutually complementary, interlocking edge contours, and the sheet metal components are joined with their edge contours by forming a connecting section to create a sheet metal unit in a form-fitting manner, wherein the sheet metal unit is then placed in a forming device and formed into the sheet metal part.

[0004] The object of the invention is therefore to at least partially solve the problems described with reference to the prior art and, in particular, to provide a method for producing a connection between flat materials, with which connection areas can be formed between a plurality of flat materials that have a minimal installation space requirement. Furthermore, a coupling for a motor vehicle drive train is also provided, in which a connection area between a pendulum flange and two outer lamella carriers is designed to be particularly space-saving.

[0005] These problems are solved by a method and a coupling according to the features of the independent claims. Further advantageous embodiments of the invention are specified in the dependent claims. It should be noted that the features listed individually in the dependent claims can be combined with one another in any technologically meaningful way and define further embodiments of the invention. Furthermore, the features specified in the claims are further specified and explained in the description, which also presents further preferred embodiments of the invention.

[0006] The inventive method for producing a connection between flat materials comprises at least the following steps: a) Providing a first flat material with at least one tab; b) Providing a second flat material with at least one pocket, wherein an inner contour of the at least one pocket corresponds at least partially to an outer contour of the at least one flap; c) Inserting at least one tab of the first flat material into at least one pocket of the second flat material, so that the first flat material and the second flat material are interlocked; d) Forming the outer contour of the at least one tab or the inner contour of the at least one pocket in a forming area, such that the outer contour of the at least one tab and the inner contour of the at least one pocket overlap at least partially in the forming area in the direction of a material plane; e) wherein the first and the second flat material are fixed perpendicular to the plane of the material.

[0007] The method according to the invention can be used in particular for joining two components in the assembly of couplings for the powertrain of automobiles. The first flat material and the second flat material are preferably plastic sheets and / or sheet metal components having a material thickness of 0.1 mm to 30 mm, particularly preferably 0.1 mm to 10 mm, or most preferably 0.1 mm to 5 mm. The second flat material has a pocket with an inner contour, which is a material recess or an opening in the second flat material that can be formed at any point on the second flat material from one surface to the opposite surface. Preferably, the at least one pocket is arranged (directly) on a second edge of the second flat material, so that the at least one pocket is at least partially open towards a material plane.The term "material plane" refers to the plane into which the first flat material and the second flat material extend. "Towards the material plane" refers to all directions lying within the material plane. It is particularly preferred that the at least one pocket is spaced a certain distance from the second edge of the second flat material, wherein the distance is 1 mm to 100 mm, preferably 1 mm to 50 mm, or most preferably 1 mm to 25 mm. Furthermore, it is preferred that the second flat material has a plurality of pockets that are regularly spaced apart. In this respect, it is also particularly preferred that the pockets are distributed over the entire second edge and / or edge region or circumference and / or circumferential region of the second flat material, particularly at regular intervals.

[0008] The first flat material has at least one tab, the inner contour of which corresponds at least partially to the outer contour of which corresponds at least partially to the outer contour of which corresponds at least partially or completely to the outer contour of which corresponds at least partially or completely to the outer contour of which corresponds at least one tab, so that the tab can be inserted into the pocket, taking into account appropriate tolerances. This allows the first flat material to be connected to the second flat material in a play-free and / or form-fit manner in the direction of the material plane.

[0009] According to step c), at least one tab of the first flat material is inserted into at least one pocket of the second flat material (puzzle-like), so that the first and second flat materials interlock. This means, in particular, that the first and second flat materials do not (exclusively) lie on top of each other, but rather overlap at least partially or even completely in a connection area, orthogonally to the material plane.

[0010] Subsequently, the outer contour of the at least one tab and / or the inner contour of the at least one pocket is formed in a forming area according to step d), such that the outer contour of the at least one tab and the inner contour of the at least one pocket overlap at least partially in the forming area in the direction of the material plane. This overlap of the outer contour of the at least one tab and the inner contour of the at least one pocket fixes the first flat material and the second flat material orthogonally to the material plane. The forming is carried out in particular by a pressing process and / or by crimping, whereby the first flat material and / or the second flat material are plastically deformed, thereby in particular reducing the material thickness in the forming area and changing the inner contour and / or the outer contour in the direction of the material plane.

[0011] Preferably, the at least one flap has at least one recess that corresponds to at least one protrusion of the pocket, or the pocket has at least one recess that corresponds to at least one protrusion of the flap. This means, in particular, that the flap and / or the pocket have at least one protrusion that engages in at least one recess of the at least one flap and / or the at least one pocket, thus preventing the at least one flap from disengaging from the at least one pocket in the direction of the material plane.

[0012] Preferably, at least one recess or protrusion is semicircular. Such a geometry of the recess and / or protrusion is particularly advantageous from a manufacturing perspective.

[0013] Furthermore, it is advantageous if the at least one recess or the at least one protrusion is arranged on a flank of the at least one recess or the at least one protrusion. The flank is a lateral region of the at least one recess or the at least one protrusion. The at least one recess and / or the at least one protrusion preferably each have two lateral flanks that are connected to each other by a head region.

[0014] It is particularly advantageous if the at least one recess has an embossed feature. This embossing is a reduction in material thickness, for example in the form of a groove or a chamfer, of the first flat material and / or the second flat material in the area of ​​the inner contour and / or the outer contour of the at least one recess. The embossing preferably has a width of up to 5 mm, more preferably up to 3 mm, and most preferably up to 1 mm, perpendicular to the course of the inner contour and / or the outer contour and in the direction of the material plane, and extends, in particular on both surfaces of the first flat material and / or the second flat material, along the outer contour and / or inner contour of the recess.The embossing of the at least one recess proposed here facilitates the forming of the outer contour of the at least one tab and / or the inner contour of the at least one pocket in the forming area according to step d), so that the outer contour of the at least one tab and the inner contour of the at least one pocket in the forming area overlap at least partially in the direction of the material plane.

[0015] In a further development of the invention, it is proposed that the inner contour of the at least one pocket and the outer contour of the at least one flap are aligned such that the connection between the first flat material and the second flat material is free of play and form-fitting. This means, in particular, that the inner contour of the at least one pocket and the outer contour of the at least one flap are aligned orthogonally to the material plane.

[0016] Furthermore, it is proposed that the thickness of a connection area between the first and second flat materials should be at most equal to the thickness of either the first or the second flat material. This results in a particularly space-saving connection area. The connection area is the area containing at least one pocket and at least one flap. In other words, the connection area, perpendicular to the material plane, is no thicker than either the thickness of the first or the thickness of the second flat material.

[0017] Furthermore, it is advantageous if the at least one pocket is spaced apart from a second edge of the second flat material. This means, in particular, that the at least one pocket is completely surrounded by the second flat material in the direction of the material plane. In other words, the at least one pocket is an opening or hole in the surface of the second flat material.

[0018] It is particularly advantageous if the outer contour of at least one tab and the inner contour of at least one pocket overlap in a C-shape within the forming area. This C-shaped overlap is specifically orthogonal to the material plane. This has the advantage that the first flat material and the second flat material are fixed orthogonally to the material plane in both directions.

[0019] According to a further aspect of the invention, a coupling for a drive train of a motor vehicle is proposed, comprising a first flat material with at least one tab and a second flat material with at least one pocket, wherein a tab of the first flat material is arranged in the at least one pocket of the second flat material to form a connection area, wherein an inner contour of the at least one pocket or an outer contour of the at least one tab is formed in a forming area such that the inner contour of the at least one pocket and the outer contour of the at least one tab at least partially overlap in the forming area in the direction of a material plane of the first flat material and the second flat material, wherein the first and the second flat material are fixed perpendicular to the material plane.

[0020] The basic design of the coupling proposed here is known, for example, from DE 10 2009 006 648 A1 and DE 10 2009 042 836 A1. The coupling proposed here is characterized in particular by the fact that the first flat material and the second flat material are joined to each other using the method according to the invention. In this respect, reference is made to the description of the method according to the invention.

[0021] Preferably, the first flat material is at least an outer lamella carrier and the second flat material is a pendulum flange.

[0022] According to a further aspect of the invention, a motor vehicle is proposed which has a drive unit with an output shaft, a drive train and a clutch according to the above description, wherein the clutch is arranged to detachably connect the output shaft to the drive train.

[0023] The vehicle is driven by the drive unit, which can be detachably connected to the vehicle's drivetrain via a friction clutch. This allows the torque and rotational speed to be used for propulsion with variable gear ratios, while the drive unit can remain continuously in operation. By using the (friction) clutch as described above, the rotating weight can be reduced and the efficiency of such a vehicle increased.

[0024] According to another advantageous embodiment of the motor vehicle, the drive unit is arranged in the motor vehicle in front of a driver's cabin and transversely to a longitudinal axis of the motor vehicle.

[0025] Most modern motor vehicles are front-wheel drive and therefore preferably position the drive unit, such as an internal combustion engine or an electric motor, in front of the driver's cab and transversely to the main direction of travel. With such an arrangement, the available installation space is particularly limited, making the use of a compact clutch especially advantageous.

[0026] The installation space situation is exacerbated in passenger cars classified as small cars according to European standards. The components used in a small car are not significantly smaller than those in larger passenger cars. Nevertheless, the available installation space is considerably smaller. The friction clutch described above is compact, lightweight, and inexpensive to manufacture, making it particularly suitable for small cars. Passenger cars are classified into vehicle classes based on factors such as size, price, weight, and performance, although this definition is constantly evolving to meet market demands. In the US market, vehicles in the small car and microcar classes are classified as subcompact cars according to European standards, while in the British market, they correspond to superminis or city cars.Examples of the microcar class are the Volkswagen Fox or the Renault Twingo. Examples of the subcompact car class are the Alfa Romeo Mito, Volkswagen Polo, Ford Fiesta, or Renault Clio.

[0027] The invention and its technical context are explained in more detail below with reference to the figures. It should be noted that the figures show particularly preferred embodiments of the invention, but that the invention is not limited to these. They schematically depict: Fig. 1: a first flat material and a second flat material after process step c); Fig. 2: the first flat material and the second flat material after process step d); Fig. 3: a cross-sectional view through a connection area of ​​the first flat material and the second flat material after process step d) according to Fig. 2; Fig. 4: A perspective view of a coupling for a motor vehicle drivetrain; Fig. 5: the clutch for a drive train of a motor vehicle according to Fig. 4 in a front view; Fig. 6: A detailed view of a flap and a pocket of the clutch according to the Fig. 4 and Fig. 5 after procedure step c); Fig. 7: the bag and flap of the clutch according to Fig. 6 after procedure step d); Fig. 8: a sectional view through a connection area of ​​the pocket and flap according to Fig. 7; and Fig. 9: a motor vehicle with a drive unit.

[0028] The Fig. Figure 1 shows a flat material 1 with a tab 3, the tab 3 projecting from a first edge 15 of the first flat material 1 towards a material plane 8 (not shown here). The tab 3 has two lateral flanks 11, each with a semicircular recess 9. Furthermore, the Fig. 1 a second flat material 2 with a pocket 4, wherein the pocket 4 is arranged directly on a second edge 22 of the second flat material 2. The pocket 4 has a semicircular protrusion 10 in each of its lateral regions, which projects into the recesses 9 of the flap 3. The flap 3 has an outer contour 6 which essentially corresponds to an inner contour 5 of the pocket 4. Fig. Figure 1 shows the situation after step c), after the tab 3 of the first flat material 1 has been inserted into the pocket 4 of the second flat material 2. The first flat material 1 and the second flat material 2 are thus interlocked, so that the first flat material 1 and the second flat material 2 are fixed in the (not shown here) material plane 8 (corresponding to the drawing plane). The tab 3 and the pocket 4 form a connection area 13. It should be noted here that the outer contour 6 of the tab 3 and the inner contour 5 of the pocket 4 do not overlap in the connection area 13 orthogonally to the (not shown here) material plane 8, i.e., perpendicular to the drawing plane, after step c), so that the tab 3 can be inserted into the pocket 4 (like a puzzle). Furthermore, the recesses 9 each have an embossing 21 along the outer contour 6 of the tab 5.

[0029] The Fig. Figure 2 shows a situation after step d). In particular, in the Fig. 2. It can be seen that the protrusions 10 of the pocket 4 of the second material 2 are formed in a forming area 7 such that the inner contour 5 now overlaps with the outer contour 6 of the flap 3 of the first flat material 1 in the direction of the (not shown here) material plane 8. This is particularly evident from the fact that the protrusions 10 overlap the embossings 21 of the recesses 9 (at least partially), so that the first flat material 1 and the second flat material 2 are now also fixed perpendicular to the drawing plane.

[0030] The Fig. Figure 3 shows a cross-sectional view along the in Fig. Section III-III shown in Figure 2. The tab 3 of the first flat material 1 is visible in the pocket 4 of the second flat material 2. Furthermore, it can be seen that the recesses 9 in the tab 3 have indentations 21, with the protrusions 10 overlapping the indentations 21 after forming in a forming area 7. The outer contour 6 of the tab 3 and the inner contour 5 of the pocket 4 therefore overlap in the forming area 7 in a C-shape. In addition, the Fig. 3, that a thickness 12 of the connection area 13 corresponds at most to a material thickness 14 of the first flat material 1 or the second flat material 2. Furthermore, the Fig. 3 the material plane 8, which runs along an extension direction of the first flat material 1 and the second flat material 2, parallel to a surface 23 and centrally through the first flat material 1 and the second flat material 2.

[0031] The Fig. Figure 4 shows a schematic exploded view of a coupling 16 of a drive train 17 of a motor vehicle 18. The coupling 16 has a pivot flange 19 and two outer plate carriers 20. In the circumferential direction and spaced apart from a second edge 22, a plurality of regularly spaced pockets 4 with an inner contour 5 are formed in a surface 23 of the pivot flange 19. The outer plate carriers 20 have tabs 3 with an outer contour 6 that correspond to the pockets 4 of the pivot flange 19.

[0032] The Fig. 5 now shows the coupling 16 of the Fig. 4 in a front view, after the tabs 3 of the outer lamella carriers 20 have been inserted into the pockets 4 of the pendulum flange 19.

[0033] The Fig. Figure 6 shows a detailed view of a tab 3 of the outer lamella carrier 20 and a pocket 4 of the pendulum flange 19 of the Fig. 5 after step c). The tab 3 has recesses 9 with embossings 21 on its lateral flanks 11. Correspondingly, the tab 4 has protrusions 10 that project into the recesses 9 of the tab 3. The tab 3 and the pocket 4 form a connection area 13, so that the pendulum flange 19 and the two outer lamella supports 20 are fixed to each other in the (not shown here) material plane 8. However, it should be clarified that the outer contour 6 of the tab 3 corresponds to the inner contour 5 of the pocket 4, that is, it is perpendicular to the drawing plane or orthogonal to the (not shown here) material plane 8, so that the pendulum flange 19 and the two outer lamella supports 20 are not yet fixed in this direction after step c).

[0034] This is only the case if, according to step d), as in Fig. As shown in Figure 7, the inner contour 5 of the pocket 4 of the pendulum flange 19 was formed in a forming area 7 such that the protrusions 10 overlap the indentations 21 of the recesses 9 of the tab 3 of the outer lamella carrier 20, so that the outer contour 6 of the tab 3 and the inner contour 5 of the pocket 4 intersect in the forming area 7 in the direction of the (not shown here) material plane 8. The tab 3 and the pocket 4 form a connection area 13.

[0035] Fig. Figure 8 shows a cross-sectional view along the line in the Fig. Section VIII-VIII shown in section 7 through the connection area 13. The Fig. 8 corresponds Fig. 3, provided that the first flat material 1 is the two outer lamella supports 20 and the second flat material 2 is the pendulum flange 19. In this respect, regarding the Fig. 8 on the description of the Fig. 3 referred to. Furthermore, it should be noted that the outer lamella carriers 20 touch each other with their surfaces 23 in a central area in the connection area 13.

[0036] Fig. Figure 9 schematically shows a motor vehicle 18 with a drive unit 24, for example, an internal combustion engine and / or an electric motor. The drive unit 24 has an output shaft 25, which is connected to a drive train 17 via a clutch 16 as described above. The axis of rotation 26 defines the axis of rotation of the output shaft 25, the clutch 16, and the drive train 17. The clutch 16 is, in particular, a friction clutch in which the torque of the drive unit 24 is detachably transmitted from the output shaft 25 to at least one drive shaft in the drive train 17 via frictional engagement and various friction partners. The drive unit 24 is preferably mounted transversely in front of a driver's cab 27.

[0037] The connection technology described here is characterized in particular by a reduced installation space requirement in connection area 13. Reference symbol list 1 first flat material 2 second flat material 3 tabs 4 bags 5 Inner contour 6 Outer contour 7 Forming area 8 Material level 9 recess 10 Protrusion 11. Flank 12 Thickness 13 Connection area 14 Material thickness 15 first margin 16 Clutch 17 Powertrain 18 Motor vehicle 19 Pendulum flange 20 external slat carriers 21. Coinage 22 second margin 23 Surface 24 drive unit 25 Output shaft 26 axis of rotation 27 Driver's cab

Claims

Method for producing a connection between flat materials (1, 2), comprising at least the following steps: a) providing a first flat material (1) with at least one tab (3); b) providing a second flat material (2) with at least one pocket (4), wherein an inner contour (5) of the at least one pocket (4) corresponds at least partially to an outer contour (6) of the at least one tab (3); c) inserting the at least one tab (3) of the first flat material (1) into the at least one pocket (4) of the second flat material (2), such that the first flat material (1) and the second flat material (2) are interlocked;d) Forming the outer contour (6) of the at least one tab (3) or the inner contour (5) of the at least one pocket (4) in a forming area (7) such that the outer contour (6) of the at least one tab (3) and the inner contour (5) of the at least one pocket (4) overlap at least partially in the forming area (7) in the direction of a material plane (8); e) wherein the first and the second flat material (1, 2) are fixed perpendicular to the material plane (8). Method according to claim 1, wherein the at least one tab (3) has at least one recess (9) which corresponds to at least one protrusion (10) of the pocket (4), or wherein the pocket (4) has at least one recess (9) which corresponds to at least one protrusion (10) of the tab (3). Method according to claim 2, wherein the at least one recess (9) or the at least one protrusion (10) is semicircular. Method according to claim 2 or 3, wherein the at least one recess (9) or the at least one protrusion (10) is arranged on a flank (11) of the at least one recess (9) or the at least one protrusion (10). Method according to one of claims 2 to 4, wherein the at least one recess (9) has an embossing. Method according to one of the preceding claims, wherein the inner contour (5) of the at least one pocket (4) and the outer contour (6) of the at least one flap (3) are aligned such that the connection between the first flat material (1) and the second flat material (2) is free of play and form-fitting. Method according to one of the preceding claims, wherein a thickness (12) of a connection area (13) of the first flat material (1) and the second flat material (2) corresponds at most to a material thickness (14) of the first flat material (1) or of the second flat material (2). Coupling (16) for a drive train (17) of a motor vehicle (18), comprising a first flat material (1) with at least one tab (3) and a second flat material (2) with at least one pocket (4), wherein a tab (4) of the first flat material (1) is arranged in the at least one pocket (4) of the second flat material (2) to form a connection area (13), wherein an inner contour (5) of the at least one pocket (4) or an outer contour (6) of the at least one tab (3) is formed in a forming area (7) such that the inner contour (5) of the at least one pocket (4) and the outer contour (6) of the at least one tab (3) at least partially overlap in the forming area (7) in the direction of a material plane (8) of the first flat material (1) and the second flat material (2), wherein the first and the second flat material (1, 2) are fixed perpendicular to the material plane (8). Coupling (16) according to claim 8, wherein the first flat material (2) is at least one outer lamella carrier (20) and the second flat material (2) is a pendulum flange (19). motor vehicle (18) comprising a drive unit (24) with an output shaft (25), a drive train (17) and a clutch (16) according to claim 8 or 9 for detachably connecting the output shaft (25) to the drive train (17).

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