CONNECTING ELEMENT FOR PRODUCING A FRICTION-WELDING CONNECTION

Abstract

The invention relates to a connecting element (10, 20, 30, 50) for producing a component connection (70) of two components (72, 74; 92) lying against each other by means of the connecting element (IO, 20, 30, 50), which is welded to the lower layer (74)the base layerby friction, wherein the connecting element (10, 20, 30, 50) has a shaft (18), which has a shaft segment (14) and a head (12) having a flat surface (20) lying on the top side of the head for transmitting the axial force, wherein a drive cutout (22, 32) is introduced into the flat surface (20) in order to transmit a torque. The invention is characterized in that a continuous diameter increase starting at an ascent level (A) on the shaft segment (18) to the bottom side of the head results, wherein the distance from the ascent level (A) to a head bottom-side level (K), which has the greatest distance from the shaft end, is less than half the difference between the head outside diameter and the shaft diameter at the ascent level (DADs)/2 (D2) and greater than a quarter of the difference between the head outside diameter and the shaft diameter at the ascent level (DADs)/4 (D1).

Claims

1-19. (canceled)

20. Connecting element (10, 20, 30, 50) for producing a component connection (70), comprising: two components (72, 73; 92) lying against each other by means of the connecting element (10, 20, 30, 50) which is welded to the lower layer (74)the base layerby friction; wherein said connecting element (10, 20, 30, 50) has a shaft (16) which has a shaft segment (14) and a head (12) having a flat surface (20) on the top side of the head for transmitting an axial force; wherein a drive cutout (22, 32) has been formed in the flat surface (20) in order to transmit a torque; a continuous diameter increase starting at an ascent level (A) on the shaft segment (16) to the bottom side of the head results; wherein the distance of the ascent level (A) from a head underside level (K) is at a maximum distance from the shaft end, is less than half the difference between the outside diameter of the head and the shaft diameter at the ascent level (D.sub.AD.sub.S)/2 (D.sub.2) and greater than a quarter of the difference between the outside diameter of the head and the shaft diameter at the ascent level (D.sub.AD.sub.S)/4 (D.sub.1).

21. Connecting element according to claim 20 characterized in that the slope (M1) at the ascent level (A) forms an angle (.sub.1) of less than 80 with the normal.

22. Connecting element according to claim 20 characterized in that the first shaft segment (14) is cylindrical.

23. Connecting element according to claim 20 characterized in that the depth (t) of the drive cutout (22, 32) is less than 30% of the radial extension (a) of the drive cut-out (22, 32).

24. Connecting element according to claim 20 characterized in that the edge region of the head (12) tapers off at an angle of between 85 and 95, in particular 90, relative to the axis of rotation of the connecting element (10, 30).

25. Connecting element according to claim 20 characterized in that the diameter increases according to a function, whichin the axial direction of the headhas a first slope (M1, .sub.1) and a second slope (M2, .sub.2) with respect to the normal relative to the axis of rotation (R), said second slope (M2, .sub.2) being smaller than said first slope (M1, .sub.1).

26. Connecting element according to claim 25 characterized in that the diameter increases according to a function, whichin the axial direction of the head (12)has a first slope (M1, .sub.1) and a second slope (M2, .sub.2) and a third slope (M3, .sub.3) with respect to the normal relative to the axis of rotation (R), said second slope (M2, .sub.2) being smaller than said first slope (M1, 1) and said third slope (M3, .sub.3) being smaller than said second slope (M2, .sub.2).

27. Connecting element according to claim 26 characterized in that such increase occurs along a curvature whose radius is in particular larger than the distance of the point from the underside of the head.

28. Connecting element according to claim 20 characterized in that the connecting element tapers conically at the end of the shaft, in particular at a taper angle of between 60 and 80.

29. Connecting element according to claim 28 characterized in that at the end of the shaft, a cylindrical segment (19) follows after the cone (18).

30. Component connection (70), comprising: a base layer (74) and at least one top layer (72, 92, 46); connecting element (76) comprising a head (12) and a shaft (16); said connecting element (76) cohesively connects to said base layer (48, 74) via its front face; material from said top layer (72, 92, 46) at least partially surrounds the head (12) laterally above the level of said top layer (72, 92, 46).

31. Component connection (70) according to claim 30, characterized in that: said connecting element (76) comprises: two components (72, 73; 92) lying against each other by means of the connecting element (10, 20, 30, 50) which is welded to the lower layer (74)the base layerby friction; wherein said connecting element (10, 20, 30, 50) has a shaft (16) and a head (12), said shaft has a shaft segment (14) and said head (12) has a flat surface (20) on said top side for transmitting an axial force; a drive cutout (22, 32) formed in said flat surface (20) of said head in order to transmit a torque; a continuous diameter increase starting at an ascent level (A) on said shaft segment (16) to said bottom side of said head; and, wherein the distance of the ascent level (A) from a head underside level (K), which is at a maximum distance from the shaft end, is less than half the difference between the outside diameter of the head and the shaft diameter at the ascent level (DADS)/2 (D2) and greater than a quarter of the difference between the outside diameter of the head and the shaft diameter at the ascent level (DADS)/4 (D1).

32. Setting tool (40) for producing a component connection (70), comprising: said component connection comprises: a base layer (74) and at least one top layer (72, 92, 46); connecting element (76) comprising a head (12) and a shaft (16); said connecting element (76) cohesively connects to said base layer (48, 74) via its front face; and, material from said top layer (72, 92, 46) at least partially surrounds the head (12) laterally above the level of said top layer (72, 92, 46); said setting tool (40) comprises a hold-down device (42, 80, 96) and a drive bit (44, 82), said drive bit (44, 82) has a flat base (54) on its front face, with raised drive structures (56) being provided on said base (54); and, said base (54) is surrounded by a raised border (60) which defines a cavity together with the internal diameter (D1) of the border.

33. Setting tool according to claim 32 characterized in that said hold-down device (96) has a taper (98) on its front face.

34. Setting tool according to claim 32 above characterized in that at least two suction bores (58) are provided in the base (54).

35. Setting tool according to claim 34 characterized in that said suction bores (58) are tangent to a radius (U) whose distance from the border (60) is at least 5% of the internal diameter (D.sub.1) of the border.

36. Setting tool according to claim 34 characterized in that the border (60) has a taper on its front face.

37. Connecting system, comprising: a setting tool, said setting tool comprises: a hold-down device (42, 80, 96) and a drive bit (44, 82), said drive bit (44, 82) has a flat base (54) on its front face, with raised drive structures (56) being provided on said base (54); and, said base (54) is surrounded by a raised border (60) which defines a cavity together with the internal diameter (D1) of the border; and, a connecting element, said connecting element comprises two components (72, 73; 92) lying against each other by means of the connecting element (10, 20, 30, 50) which is welded to the lower layer (74)the base layerby friction; wherein the connecting element (10, 20, 30, 50) has a shaft (16) and a head; said shaft has a shaft segment (14); said head (12) having a flat surface (20) on the top side of said head for transmitting an axial force; a drive cutout (22, 32) formed in said flat surface (20) in order to transmit a torque, a continuous diameter increase starting at an ascent level (A) on said shaft segment (16) to the bottom side of said head; and wherein the distance of the ascent level (A) from a head underside level (K), which is at a maximum distance from the shaft end, is less than half the difference between the outside diameter of the head and the shaft diameter at the ascent level (D.sub.AD.sub.S)/2 (D.sub.2) and greater than a quarter of the difference between the outside diameter of the head and the shaft diameter at the ascent level (D.sub.AD.sub.S)/4 (D.sub.1), the internal diameter (D.sub.1) of the border is at least 10% larger than the diameter (D.sub.A) of the head of the connecting element.

38. Connecting system according to claim 37 characterized in that the height (HU) of the border is larger than or equal to the maximum extension of the head in an axial direction.

Description

[0045] Throughout the description, claims and drawings, those terms and associated reference signs are used as are listed in the List of Reference Signs below. In the drawings,

[0046] FIG. 1a is a lateral view of a connecting element according to the invention;

[0047] FIG. 1b is a perspective view of a connecting element according to the invention;

[0048] FIG. 1c is a partial sectional view of the connecting element;

[0049] FIG. 2 is a perspective view of a connecting element according to the invention;

[0050] FIG. 3 is a schematic sectional view of a setting tool according to the invention;

[0051] FIG. 4a is perspective view of the front-face end of the drive bit of FIG. 3;

[0052] FIG. 4b is a top view of the front face of the drive bit of FIG. 4a;

[0053] FIG. 5 is a partial sectional view of a drive bit with a connecting element inserted in it;

[0054] FIG. 6 is a sectional view of component connection produced at the end of a setting process;

[0055] FIG. 6a is an enlarged view of a detail of FIG. 6, and

[0056] FIG. 7 is an enlarged view of a detail similar to FIG. 6a.

[0057] FIG. 1a is a lateral view of a connecting element 10 according to the invention. The connecting element 10 comprises a head 12 and a shaft 14, which shaft 14 has a cylindrical portion 16. On the cylindrical portion 16, starting at an ascent level A, the shank continuously widens until up to the underside of the head at a head level K. The head level K is the level which is at the maximum distance from the shaft end. For the present connecting element 10, this is the edge of the head.

[0058] The continuous increase in diameter proceeds along a curvature of a curvature radius R. The increase in diameter starts at an ascent level A which is located at a distance of between D1=(D.sub.AD.sub.S)/4 and D2=(D.sub.AD.sub.S)/2 from the head underside level K. This embodiment produces a displacement behavior in the case of a thin cover plate which is described in more detail with reference to FIG. 2.

[0059] Furthermore, the end of the connecting element 10 which faces away from its head has a conical portion 18. The presence of this conical portion 18 results in a reduction of the front face of the shaft. As a result, the connecting element will be centered better during introduction. The illustrated connecting element 10 moreover has a cylindrical projection following its conical portion which easily penetrates a top layer and thus further improves the centering of the connecting element 10.

[0060] In this embodiment, the diameter increases with a continuous decrease in slope with respect to the normal N relative to the screw axis, which diameter also comprises a first slope M1(1) and a subsequent second slope M2(.sub.2).

[0061] FIG. 1b is a perspective view of a connecting element 10 according to the invention, which has an inner drive 22 provided in its flat head surface 20, which screw drive 22 is in the form of a cross recess.

[0062] FIG. 1c is a partial sectional view of a connecting element 10, which view shows that the depth t of the screw drive is only 30%, at the most, of the maximum extension a of the drive in a radial direction. Such a design is possible because the axial forces required for the friction-welding connection are transmitted via the flat head 20. As the inner drive needs to be spaced a certain distance from the shaft 16 owing to the heat generated in the friction-welding process, the low drive depth t allows for a low axial extension of the head and thus a low structural height.

[0063] FIG. 2 is a perspective view of a connecting element 30 according to the invention, whichin contrast to the connecting element shown in FIG. 1bhas a drive recess 32 in the form of a five-pointed star. This improves the transmission of torque in the case of a high temperature increase. The dotted line indicates the radius of the drive structure and its maximum extension a in a radial direction.

[0064] FIG. 3 is a schematic sectional view of a setting tool 40 according to the invention. The setting tool 40 comprises a hold-down device 42 and a drive bit 44. The hold-down device 42 is used to press the component layers 46, 48 together during the connection process. The drive bit 44 is rotatably mounted relative to the hold-down device 42 and presses down on and rotates the connecting element 50 so as to introduce it into the component layers 46, 48. The material of the upper top layer 46 is preferably a light metal, in particular aluminum, whereas the base layer 48 is made of high-tensile steel. The drive bit 44 has a central suction channel 52 which can be used to generate a negative pressure on the contact surface so as to hold the connecting element 50 on the drive bit 44 during the connecting process. The design of the front face end of the drive bit 44 will be explained in more detail with reference to the following FIGS. 4a, 4b.

[0065] FIG. 4a is a perspective view of the front face end of the drive bit 44. The drive bit 44 has a flat base 54. Raised drive structures 56 are provided on the flat base 54 which are used to drive a matching connecting element with an inner drive, in which case the axial force is transmitted to the connecting element via the flat base. Between the drive structures 56 suction bores 58 are provided which are connected to the central suction channel so as to communicate with it. The flat base 54 is surrounded by a border 60 which is raised relative to the flat base 54.

[0066] FIG. 4b is a top view of a front face of the drive bit 44. The suction bores 58 contact a radius U. The border 60 has an internal diameter D1. The border and the radius U are concentric, with the diameter DU of the radius U being approx. 65% of the internal diameter D1 of the border. Consequently, suction con-tact can even be made with the edge region of connecting elements having a substantially smaller head diameter than the internal diameter D1 of the border. The suction points on the connecting element are then ideally arranged at a distance from the center of the connecting element.

[0067] FIG. 5 is a partial sectional view of a drive bit 44 with a connecting element 10 inserted therein. The drive bit 44 has a central suction channel 52 to which the suction bores 58 are connected. The inserted connecting element 10 has a head diameter D.sub.K which is approx. 90% of D1. In this view the height Hu of the raised border 60 can be seen particularly well. The border extends beyond the head underside level K of the connecting element. This ensures that any material radially displaced to the outside during setting will be entrained by the drive bit and directed such that it cannot enter the space between the hold-down device (not shown) surrounding the drive tool and the drive bit. The area between the head level K and the flat base 54 can receive material from the top layer, which allows the structural height to be maintained with a reduced diameter.

[0068] FIG. 6 is a sectional view of a component connection 70 produced at the end of a setting process. The component connection 70 comprises a top layer 72 and a base layer 74 which layers are connected to each other by means of a connecting element 76. The connecting element 76 is cohesively connected to the base layer by means of welding, whereas the top layer 72 is positively held on the connecting element 76. Furthermore, a setting tool 78 is indicated which comprises a hold-down device 80 which presses down on the component connection, thus clamping the top layer 72 and the base layer 74 together.

[0069] The drive bit 82 has a border 84 of a height sufficient to ensure that, upon completion of the setting process, the border will abut on the level of the top layer 72 and thus be flush with the hold-down device 80.

[0070] FIG. 6a is an enlarged view of a detail of FIG. 6. This view shows particularly well how softened and displaced material from the top layer 72 is received between the head and the material of the connecting element 76 which rises during the friction-welding process performed on the base layer 74. Because the hold-down device 80 and the border 84 will come to abut on the same level at the end of this process, only a minor taper is required on the hold-down device 80 since the material from the top layer 72 will predominantly be retained within the border 84 and the hold-down device 80 itself does not primarily serve as a mold.

[0071] FIG. 7 is an enlarged view of a detail similar to the view of FIG. 6. In the design illustrated in FIG. 7, the border 94 is chosen such that it will be spaced from the level of the top layer 92 by a distance S at the end of the setting process. As a result, the border 94 will redirect any material displaced from the top layer 92 during the friction-welding process in such a way that it will not enter the space between the drive bit and the hold-down device 96, and still allow the material displaced from the top layer 92 to also be confined by the hold-down device 96 in this design. Because the maximum structural dimensions are as a rule defined by the hold-down device 96, additional receiving volume can be created in this way, thus allowing the overall height to be reduced further while maintaining the same external dimensions. In this embodiment, the hold-down device 96 is provided with a taper along its inner edge. This facilitates removal of the hold-down device 96 following the setting process since it prevents the hold-down device 96 from becoming stuck on the transformed material from the top layer 92.