Method for manufacturing a bearing shell assembly and bearing shell assembly for a ball joint

1. A ball joint comprising:

a ball joint housing;

a bearing shell disposed in the housing and having a plastic extension; and

a spring element arranged in a region of the plastic extension, wherein an outer circumference of the spring element is free and radially spaced from the ball joint housing, wherein the spring element includes an opening for receiving the plastic extension, wherein the opening defines a continuous and non-deformable inner diameter, wherein the spring element is a plate spring or an assembly of several plate springs;

wherein a free axial end of the plastic extension, which is not within the region of the spring element includes a continuously encircling non-deformable build-up which defines a first external diameter, and the plastic extension, which is directly adjacent the free axial end and within the region of the spring element defines a second external diameter which is less than the first external diameter to thereby non-releasably fasten the spring element to the bearing shell only in the region of the plastic extension of the bearing shell which is directly adjacent the free axial end thereof.

2. The ball joint of claim 1 , wherein the bearing shell and the plastic extension are produced as an integral injection-molded part.

3. The ball joint of claim 1 , wherein the plastic extension is a substantially hollow extension.

4. The ball joint of claim 1 , wherein the continuously encircling build-up of the free axial end is formed during a deformation process and prior to the deformation process an outer side of the free axial end is conical.

5. The ball joint of claim 1 , wherein the continuously encircling build-up of the free axial end is formed during a deformation process.

6. The ball joint of claim 1 , wherein the spring element is fastened to the bearing shell by one of a hot deformation or a cold deformation of the plastic extension.

7. The ball joint of claim 1 , wherein the inner diameter of the opening of the spring element is slightly larger than the second external diameter of the plastic extension of the bearing shell.

8. A ball joint comprising:

a ball joint housing;

an injection-molded bearing shell disposed in the housing and having an integral substantially hollow plastic extension having a free axial end; and

a spring element arranged in a region of the plastic extension, wherein an outer circumference of the spring element is free and radially spaced from the ball joint housing, wherein the spring element includes an opening for receiving the plastic extension, wherein the opening defines a continuous and non-deformable inner diameter, wherein the spring element is a plate spring or an assembly of several plate springs;

wherein the free axial end of the plastic extension, which is not within the region of the spring element includes a continuously encircling non-deformable build-up which defines a first external diameter, and the plastic extension, which is directly adjacent the free axial end and within the region of the spring element defines a second external diameter which is less than the first external diameter to thereby non-releasably fasten the spring element to the bearing shell only in the region of the plastic extension of the bearing shell which is directly adjacent the free axial end thereof.

9. The ball joint of claim 8 , wherein the continuously encircling build-up of the free axial end is formed during a deformation process and prior to the deformation process an outer side of the free axial end is conical.

10. The ball joint of claim 8 , wherein the spring element is fastened to the bearing shell by one of a hot deformation or a cold deformation of the plastic extension.

11. The ball joint of claim 8 , wherein the inner diameter of the opening of the spring element is slightly larger than the second external diameter of the plastic extension of the bearing shell.

12. A ball joint comprising:

a ball joint housing;

an injection-molded bearing shell disposed in the housing and having an integral substantially hollow plastic extension; and

a spring element arranged in a region of the plastic extension, wherein an outer circumference of the spring element is free and radially spaced from the ball joint housing, wherein the spring element includes an opening for receiving the plastic extension, wherein the opening defines a continuous and non-deformable inner diameter, wherein the spring element is a plate spring or an assembly of several plate springs;

wherein a free axial end of the plastic extension, which is not within the region of the spring element includes a continuously encircling build-up which defines a first external diameter, the build-up formed by one of a hot deformation or a cold deformation process, and the plastic extension, which is directly adjacent the free axial end and within the region of the spring element defines a second external diameter which is less than the first external diameter to thereby non-releasably fasten the spring element to the bearing shell only in the region of the plastic extension of the bearing shell which is directly adjacent the free axial end thereof.

13. The ball joint of claim 12 , wherein the plastic extension has a substantially hollow extension.

14. The ball joint of claim 13 , wherein prior to the forming of the continuously encircling build-up of the free axial end by the one of the hot deformation or the cold deformation process, an outer side of the free axial end is conical.

15. The ball joint of Claim 12 , wherein the inner diameter of the opening of the spring element is slightly larger than the second external diameter of the plastic extension of the bearing shell.

16. A ball joint comprising:

a ball joint housing;

a bearing shell disposed in the housing and having a plastic extension;

a spring element arranged non-releasably in a region of the plastic extension, wherein an outer circumference of the spring element is free and radially spaced from the ball joint housing, wherein the spring element includes an opening for receiving the plastic extension, wherein the opening defines a continuous and non-deformable inner diameter; and

a housing cover fastened to the ball joint housing;

wherein the spring element is prestressed between the housing cover and the bearing shell; and

wherein a free axial end of the plastic extension, which is not within the region of the spring element includes a continuously encircling non-deformable build-up which defines a first external diameter, and the plastic extension, which is directly adjacent the free axial end and within the region of the spring element defines a second external diameter which is less than the first external diameter to thereby non-releasably fasten the spring element to the bearing shell only in the region of the plastic extension of the bearing shell which is directly adjacent the free axial end thereof.

17. The ball joint of claim 16 wherein the plastic extension is substantially hollow.

18. The ball joint of claim 17 wherein the continuously encircling build-up of the free axial end is formed during a deformation process and prior to the deformation process an outer side of the free axial end is conical.