Torque transmitting assembly and method of producing

1. A torque transmitting assembly comprising:

a generally cup shaped outer shell having a closed end, an outer wall, and an open end, the closed end having at least one raised portion formed therein independent of the outer wall, the outer wall extending from the closed end to an outwardly extending lip surrounding the open end of the outer shell, the open end of the outer shell adapted to be operatively engaged with a first rotating member; and

a generally disk shaped inner member having a central aperture and a central axis, the inner member including at least one tab extending axially outwardly therefrom, the at least one tab including a first end having at least one projection extending axially therefrom and engaging the at least one raised portion of the outer shell to facilitate a transfer of rotation between the outer shell and the inner member, the central aperture adapted to be operatively engaged with a second rotating member, wherein the inner member is received inside the outer shell.

2. The assembly according to claim 1 , wherein the outer shell is a drive shell.

3. The assembly according to claim 1 , wherein the inner member is a pinion carrier.

4. The assembly according to claim 1 , wherein the tab of the inner member is welded to the closed end of the outer shell.

5. The assembly according to claim 1 , wherein the inner member includes a central collar surrounding the central aperture of the inner member and extending axially outwardly in a direction opposite the tab.

6. The assembly according to claim 5 , wherein an annular array of teeth is formed on an inner surface of the collar.

7. The assembly according to claim 1 , wherein the outer shell includes a plurality of splines formed on an inner surface of the lip to engage the first rotating member.

8. The assembly according to claim 1 , wherein the first end of the at least one tab includes a plurality of the projections extending axially therefrom to form a saw tooth cross-sectional pattern at the first end of the at least one tab.

9. The assembly according to claim 8 , wherein the plurality of the projections engages a substantially flat surface of the at least one raised portion, the plurality of the projections including a first projection and a second projection, wherein an opening is formed between the first end of the at least one tab and the flat surface of the at least one raised portion, the opening defined by a cooperation of the first projection, the second projection, and the flat surface.

10. A torque transmitting assembly comprising:

a drive shell having a closed end, an outer wall, and an open end, the closed end having a plurality of raised portions formed thereon independent of the outer wall, the outer wall extending from the closed end to an outwardly extending lip surrounding the open end of the drive shell, the open end of the drive shell adapted to be operatively engaged with a first rotating member; and

a pinion carrier having a central aperture and a central axis, the pinion carrier including a plurality of tabs extending axially outwardly therefrom, wherein each of the tabs including a first end having at least one projection extending axially therefrom and engaging one of the raised portions of the drive shell to facilitate a transfer of rotation between the drive shell and the pinion carrier, the central aperture adapted to be operatively engaged with a second rotating member.

11. The assembly according to claim 10 , wherein the tabs of the pinion carrier are welded to the closed end of the drive shell.

12. The assembly according to claim 10 , wherein the tabs of the pinion carrier are laser welded to the closed end of the drive shell.

13. The assembly according to claim 10 , wherein the pinion carrier includes a central collar surrounding the central aperture of the pinion carrier and extending axially outwardly in a direction opposite the tabs.

14. The assembly according to claim 13 , wherein an annular array of teeth is formed on an inner surface of the central collar.

15. The assembly according to claim 10 , wherein the drive shell includes a plurality of splines formed on an inner surface of the lip to engage the first rotating member.

16. A method of producing a pinion carrier and drive shell assembly, the method comprising the steps of:

providing a drive shell having a closed end, an outer wall, and an open end, the closed end having a plurality of raised portions formed therein independent of the outer wall, the outer wall extending from the closed end to an outwardly extending lip surrounding the open end of the drive shell, the open end of the drive shell adapted to be operatively engaged with a first rotating member;

providing a pinion carrier having a central aperture and a central axis, the pinion carrier including a plurality of tabs extending axially outwardly therefrom, wherein each of the tabs including a first end having at least one projection extending axially therefrom, the central aperture adapted to be operatively engaged with a second rotating member;

inserting the pinion carrier into the drive shell; and

attaching the first end of each of the tabs of the pinion carrier to one of the raised portions of the drive shell to facilitate a transfer of rotation between the drive shell and the pinion carrier.

17. The method according to claim 16 , including the step of welding the first end of each of the tabs of the pinion carrier to the closed end of the drive shell.

18. The method according to claim 16 , including the step of laser welding the first end of each of the tabs of the pinion carrier to the closed end of the drive shell.

19. The method according to claim 16 , including the step of producing the drive shell by cold forming.

20. The method according to claim 16 , including the step of producing the drive shell by flow forming.