Abstract:
A driveshaft assembly having a first component defining a bore, a second component, which is received in the bore, and a torque ring. The torque ring is received in the bore and disposed between the first component to the second component. The torque ring includes a plurality of teeth that are at least partially elastically deformed so as to apply a radial load to the first and second components to thereby inhibit relative axial and rotational movement between the first and second components. A method for forming a driveshaft is also provided.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to driveshaft assemblies, and more particularly to a torque ring coupling for a driveshaft assembly.  
       BACKGROUND OF THE INVENTION  
       [0002]     In the manufacture of automotive driveshafts, it is commonplace to join components, such as tubing portions to one another or to end components, such as yokes and spline shafts, by welding. While this process has been effective for its intended purpose, several drawbacks have been noted. These drawbacks include, for example, the necessity that the components be made of materials that are compatibly welded to each other, the necessity that the components be machined or formed with fairly close mating tolerances to ensure that proper alignment may be achieved prior to welding, and distortion that may result from the heat that is generated during the welding operation.  
         [0003]     Accordingly, there remains a need in the art for an improved device and method for joining components of a drive shaft in a manner that resists both axial loads and relatively high torsional loads, does not generate a large amount of heat that could distort the components, is relatively inexpensive and which may permit the machining of the components to relatively more open tolerances.  
       SUMMARY OF THE INVENTION  
       [0004]     In one form, the present teachings provide a driveshaft assembly having a first component defining a bore, a second component, which is received in the bore, and a torque ring. The torque ring is received in the bore and disposed between the first component to the second component. The torque ring includes a plurality of teeth that are at least partially elastically deformed so as to apply a radial load to the first and second components to thereby inhibit relative axial and rotational movement between the first and second components.  
         [0005]     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
         [0007]      FIG. 1  is a schematic view of an exemplary motor vehicle having a driveshaft assembly constructed in accordance with the teachings of the present invention;  
         [0008]      FIG. 2  is a schematic sectional view of a portion of the driveshaft assembly of  FIG. 1 ;  
         [0009]      FIG. 3  is an illustration of a portion of the driveshaft assembly of  FIG. 1  showing the torque ring in an end view; and  
         [0010]      FIG. 4  is an exploded section view of a portion of the driveshaft assembly of  FIG. 1 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0011]     The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
         [0012]     With reference to  FIG. 1  of the drawings, a driveshaft assembly  10  constructed in accordance with the teachings of the present invention is illustrated in operative association with an exemplary motor vehicle  12 . The vehicle  12  further includes a powertrain  14  coupled via the driveshaft assembly  10  to a driveline. The powertrain  14  includes an engine  16  coupled to a transmission  18 . The driveline includes a rear axle  20  coupled to a pair of wheels  22 . While in the particular example provided the driveshaft assembly  10  is employed within a motor vehicle, it should be appreciated that the driveshaft assembly  10  may be used in various other applications.  
         [0013]     In the particular example provided, the engine  16  is mounted in an in-line or longitudinal orientation along the axis of the motor vehicle  12 . The output of the engine  16  is coupled via a conventional clutch or torque converter (not specifically shown) to the input of the transmission  18  in order to transmit rotary power thereto. The input of the transmission  18  is commonly aligned with the output of the engine  16  for rotation about a rotary axis. The transmission  18  further includes an output  24  coupled for rotation to the driveshaft assembly  10 . Drive torque is transmitted through the driveshaft assembly  10  to the rear axle  20  where it is selectively transferred to the wheels  22  in a conventional and well known manner.  
         [0014]     Turning to  FIG. 2 , a portion of the driveshaft assembly  10  is illustrated. The driveshaft assembly  10  includes a first component  26 , a second component  28 , and a torque ring  30 . Generally speaking, the first component  26  and the second component  28  may be located anywhere along the length of the driveshaft assembly  10  including the ends thereof. Moreover, in the particular example provided, the portion of the driveshaft assembly  10  that is shown illustrates a tubing to tubing interface. However, it should be appreciated that the torque ring of the present invention may be employed to couple various other components of the driveshaft assembly  10 , such as, the tubing to an end component (e.g., yoke, spline shaft) or a deadener to a slip yoke.  
         [0015]     In the particular example provided, the first component  26  is a shaft that defines a generally cylindrical inner bore  32 . The second component  28  is generally cylindrical in shape and is received into the inner bore  32  of the first component  26 . The torque ring  30  is also received within the inner bore  32  and is located between the first component  26  and the second component  28 . Placement of the torque ring  30  in this manner compresses and deforms the torque ring  30  in an at least partially elastic manner such that radial forces are applied to both the first component  26  and the second component  28 . This radial force is sufficiently high as to permit the transmission of torque between the first and second components  26  and  26  without slippage of the torque ring  30 , as well as to sufficiently engage the first and second components  26  and  28  as to resist or inhibit relative axial movement therebetween.  
         [0016]     It will be appreciated that the first and second components  26  and  28  may be formed from any desired materials and that welding compatibility is not necessary. Accordingly, it is possible with use of the torque ring of the present invention to join steel and aluminum components to one another in an accurate yet low cost manner.  
         [0017]     With additional reference to  FIGS. 3 and 4 , the torque ring  30  is an annular structure having a wall member  50  that defines an outer surface  52  and an inner surface  54 . The wall member  50  is illustrated to be formed with teeth  56  that extend about the torque ring  30  in a sinusoidally-undulating manner but it will be appreciated that other wave forms or types, which may or may not repeat, may be employed in the alternative. In a prior-to-assembly state, the outer surface  52  of the torque ring  30  defines an outer diameter that is relatively larger than the inner diameter of the bore  32  in the first component  26 , and the inner surface  54  of the torque ring  30  defines an inner diameter that is relatively larger than the outer diameter of the first component  26 .  
         [0018]     To facilitate assembly, the first component  26  may include a flared lead in  60 , which may be adapted to guide the torque ring  30  into the bore  32 , and/or a stop member  62 , which may be adapted to prevent the torque ring  30  from being pushed into the bore  32  beyond a predetermined position. The second component  28  may include a tapered shaft lead section  64 , which may be adapted to guide the torque ring  30  onto the second component  28 . The torque ring  30  may be initially installed to the bore  32  and thereafter the second component  28  may be received into the torque ring  30 . Alternatively, the torque ring  30  may be initially installed to the second component  28  and thereafter the second component  28  and the torque ring  30  inserted into the bore  32 . Also alternatively, the torque ring  30  may be installed substantially simultaneously into the bore  32  and onto the second component  28 .  
         [0019]     During installation, the outer and inner surfaces  52  and  54  deform at least partially elastically in a manner which permits the torque ring  30  to generate the radial forces that retain the assembly together. Significantly, the undulating surfaces of the torque ring  30  permit the bore  32  and the second component  28  to be formed to relatively more open tolerances as compared to process that employ welding to retain and transmit torsional loads between the components. Moreover, precision grinding is not necessary, so that turned (or in some situations, as-cast) components may be mated to one another.  
         [0020]     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.