Method for manufacturing ball joint with threaded dome cover

Abstract

The present application discloses a method for manufacturing a vehicle suspension component, comprising: inserting a cover body into a small hole of a shell, the cover body being arranged around a central axis concentric with the small hole of the shell, the cover body having a convex side and a concave side and an outer periphery arranged around the central axis, the cover body defining a threaded hole concentric with the central axis; and deforming the cover body to maintain engagement with the shell by pressing against the convex side until the cover body is at least partially deformed and the outer periphery is enlarged compared to a pre-deformed state of the cover body.

Description

Technical Field

[0001] The present application relates to a method for manufacturing a ball joint, and more particularly, to a method for manufacturing a ball joint with a cover plate. Background Art

[0002] The statements in this section merely provide background information related to the present application and may not constitute prior art.

[0003] A ball joint typically includes a housing and a stud or rod. The rod includes a ball at one end. The ball is housed in the housing and is configured to pivot therein. Typically, the rod is inserted through a first aperture at one end of the housing until the ball is located on a mating surface within the housing. The other end of the rod extends from the housing through a second aperture in the opposite end of the housing. A cover plate typically covers the first aperture of the housing to hold the ball within the housing. In a conventional ball joint, the housing is deformed (e.g., rolled) on the cover plate to secure the cover plate to the housing.

[0004] In some applications, it may be desirable to be able to apply a lubricant, such as grease, to the interior of the ball joint after the cover plate is installed. In a conventional ball joint in which the housing is deformed over the cover plate, the cover plate may be pre-drilled and tapped with the desired threads that match the threads of the desired lubricant fitting (e.g., a grease nipple). The lubricant fitting may be threaded onto the cover plate after the cover plate is secured to the housing.

[0005] However, in some ball joints, the cover plate starts out in a domed shape and deforms to a generally flatter shape until the periphery is secured to the housing. Such cover plates are not pre-tapped for lubricant fittings.

[0006] The method of the present application solves these problems, among other things, of manufacturing a ball joint having a domed cover plate. Summary of the invention

[0007] This section provides a general summary of the application, and is not a comprehensive disclosure of its full scope or all of its features.

[0008] In one form of the present application, a method for manufacturing a vehicle suspension component includes: inserting a cover body into a small hole in a shell, the cover body being arranged around a central axis concentric with the small hole of the shell, the cover body having a convex side and a concave side and an outer periphery arranged around the central axis, the cover body defining a threaded hole concentric with the central axis; and deforming the cover body to maintain engagement with the shell by pressing against the convex side until the cover body is at least partially deformed and the outer periphery is enlarged compared to a pre-deformed state of the cover body. According to multiple alternative constructions: the method also includes screwing an accessory into the threaded hole; the accessory is a grease nipple; deforming the cover body to maintain engagement with the housing includes deforming the outer periphery of the cover body radially outward into a groove defined by the housing; the method also includes inserting a pin into the threaded hole, and wherein when the pin is set in the threaded hole, the cover body is deformed to maintain engagement with the housing; the diameter of the pin is equal to the required minimum thread diameter, which is smaller than the minimum thread diameter of the threaded hole in a pre-deformed state; the method also includes deforming the threaded hole so that the diameter of the threaded hole is reduced from the pre-deformed state of the cover body; the method also includes producing the cover body, including tapping the threaded hole with a tap having a first thread size and an initial fit grade, and the method also includes screwing the accessory into the threaded hole after deforming the cover body to maintain engagement with the housing, the thread of the accessory having a first thread size and a fit grade different from the initial fit grade; the method also includes producing the cover body The method further comprises: producing the cover body, comprising tapping the threaded hole with a tap having an initial thread size, and the method further comprises screwing an accessory into the threaded hole after deforming the cover body to maintain engagement with the shell, the thread size of the thread of the accessory being smaller than the initial thread size; the method further comprises producing the cover body, comprising tapping the threaded hole with a tapered thread, and wherein deforming the cover body comprises deforming the threaded hole to reduce the taper of the tapered thread; deforming the cover body to maintain engagement with the shell by pressing a mold against a convex side of the cover body, the mold having an outer mold portion and an inner mold portion, the outer mold portion engaging the outer portion of the cover plate, and the inner mold portion engaging the inner portion of the cover plate; the threaded hole is arranged in a boss defined by the cover body after the cover body is deformed; the method further comprises inserting a rod into the shell and placing a ball arranged at a first end of the rod in the shell for pivotal movement relative to the shell, wherein the second end of the rod extends through the end of the shell, wherein deforming the cover body to maintain engagement with the shell fixes the ball in the shell.

[0009] In another form of the present application, a method for manufacturing a vehicle suspension component includes: inserting a rod into a housing so that a ball portion disposed at a first end of the rod is located within the housing and rotatable relative to the housing, and a second end of the rod extends from the housing; inserting a cover into a small hole in the housing, the cover defining a threaded hole of a first diameter; and deforming the cover so that the periphery of the cover is deformed to remain engaged with the housing and the threads of the threaded hole are deformed. The method also includes producing the cover, including tapping the threaded hole using a tap having a first thread size and an initial fit grade, and screwing an accessory into the threaded hole after deforming the cover, the threads of the accessory having the first thread size and a fit grade different from the initial fit grade; the method also includes producing the cover, including tapping the threaded hole using a tap having an initial thread size, and screwing an accessory into the threaded hole after deforming the cover, the threads of the accessory having a thread size smaller than the initial threads; the method also includes producing the cover, including tapping the threaded hole so that the threads of the threaded hole are tapered, and wherein deforming the threads of the threaded hole reduces the taper of the threads.

[0010] In yet another form of the present application, a method of manufacturing a vehicle suspension assembly includes: inserting a rod into a small hole defined in a first end of a housing so that a ball portion disposed at the first end of the rod is located within the housing and rotatable relative to the housing, and a second end of the rod extends through a small hole defined in the second end of the housing; inserting a bearing into a small hole defined in the first end of the housing so that the bearing is located on a ball seat; inserting a cover into the small hole defined in the first end of the housing, the cover defining a threaded hole of a first diameter; and deforming the cover so that an outer periphery of the cover is deformed into a circumferential groove defined by the housing and threads of the threaded hole are deformed. According to an alternative construction, the method further includes: inserting a pin into the threaded hole to limit deformation of the threads while deforming the cover.

[0011] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order that the present application may be better understood, various forms thereof will now be described, given by way of example, with reference to the accompanying drawings, in which:

[0013] Figure 1 is a perspective view of a ball joint according to the teachings of the present application;

[0014] Figure 2 yes Figure 1 A partial cross-sectional view of a ball joint showing a dome cover plate in an installed state and a lubricant fitting installed in the dome cover plate according to the teachings of the present application;

[0015] Figure 3 According to the teaching of this application Figure 2 A schematic perspective view of a dome cover in a pre-installed state;

[0016] Figure 4 yes Figure 3 A top view of a cover plate;

[0017] Figure 5 is along Figure 4 The line 5-5 shown in FIG. Figure 3 A schematic cross-sectional view of a cover plate;

[0018] Figure 6 yes Figure 1 A schematic partial cross-sectional view of a ball joint of , showing a cover plate in a pre-installed state and a mold having a first configuration according to the teachings of the present application;

[0019] Figure 7 Shown as partially installed Figure 6 A schematic partial cross-sectional view of a ball joint and a mold;

[0020] Figure 8 The cover is shown in the installed state. Figure 6 A schematic partial cross-sectional view of a ball joint and a mold;

[0021] Fig. 9 yes Figure 3 A schematic cross-sectional view of a portion of a cover plate showing a threaded hole of the cover plate in a pre-installed state according to the teachings of the present application;

[0022] Fig.10 yes Fig. 9 A schematic cross-sectional view of a portion of a cover plate showing a threaded hole in an installed state according to the teachings of the present application;

[0023] Fig.11 yes Figure 1 A schematic partial cross-sectional view of a ball joint of , showing a cover plate in a pre-installed state and a mold having a second configuration according to the teachings of the present application;

[0024] Fig.12 Shown as partially installed Fig.11 A schematic partial cross-sectional view of a ball joint and a mold;

[0025] Fig.13 The cover is shown in the installed state. Fig.12 A schematic partial cross-sectional view of a ball joint and a mold;

[0026] Fig.14 is a cross-sectional view of a cover plate having a second configuration shown in a pre-installed state in accordance with the teachings of the present application; and

[0027] Fig.15 According to the teaching of the present application, the ball and socket joint having the second structure Fig.14 A cross-sectional view of the cover in the installed state.

[0028] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present application in any way. DETAILED DESCRIPTION

[0029] The following description is merely exemplary in nature and is not intended to limit the present application, application or use. It should be understood that in all drawings, corresponding reference numerals represent identical or corresponding components and features. Examples are provided to fully convey the scope of the present application to those skilled in the art. Many specific details, such as the types of specific components, devices and methods, are set forth to provide a thorough understanding of the changes of the present application. It will be apparent to those skilled in the art that it is not necessary to use specific details and that the examples provided herein may include alternative embodiments and are not intended to limit the scope of the present application. In some examples, well-known processes, well-known device structures and well-known technologies are not described in detail.

[0030] Reference Figure 1 and Figure 2 , a vehicle suspension may include an assembly or ball joint 10. The ball joint 10 includes a stud or rod member 14 and a housing assembly 18. The rod member 14 includes a shaft portion 22 and a ball portion 24 disposed at one end 26 of the shaft portion 22. In the particular example provided, the other end 28 of the shaft portion 22 is threaded so that a nut 30 can be matingly screwed thereon, but other configurations may also be used. The ball portion 24 has a generally spherical surface 34. In the example provided, the ball portion 24 may have a flat surface away from the shaft portion 22, but other configurations may also be used.

[0031] The housing assembly 18 includes a housing body 40, a bearing 42, and a cover plate 50. In the example provided, the housing assembly 18 also includes a biasing member 52 and a lubricant fitting 54. The housing body 40 is disposed about a central axis 58 and defines an inner cavity 62. The housing body 40 defines a first aperture 66 at one axial end 68 of the housing body 40 and a second aperture 70 at another axial end 72 of the housing body 40. The first aperture 66 and the second aperture 70 lead to the exterior of the housing body 40 and to the inner cavity 62. The housing body 40 further defines a ball seat 76 that protrudes radially inwardly from a wall 78 of the housing body 40 into the inner cavity 62. The ball seat 76 includes a concave spherical surface 80. The concave spherical surface 80 mates closely with the spherical surface 34 of the ball portion 24 to seat the ball portion 24 in the inner cavity 62 and allow the ball portion 24 to pivot relative to the housing body 40. The ball seat 76 also prevents the ball portion 24 from being removed through the second aperture 70. The concave spherical surface 80 may extend circumferentially about the axis 58. In an alternative configuration, separate spherical surfaces may be spaced circumferentially about the axis 58 to seat the ball 24. With the ball 24 seated on the ball seat 76, the shaft portion 22 extends through the second aperture 70.

[0032] The wall 78 of the housing body 40 adjacent the first aperture 66 includes an annular groove 84. The annular groove 84 is disposed about the axis 58 and is defined by a shoulder 86, a radially outwardly directed recessed surface 88, and a lip 90. The shoulder 86 has an inner diameter that is smaller than the inner diameter of the lip 90, and the recessed surface 88 extends axially between the shoulder 86 and the lip 90 and is disposed to have a diameter greater than the diameter of the lip 90. In the example provided, the lip 90 defines the first aperture 66 and extends axially to the axial end 68 of the housing body 40.

[0033] The bearing 42 is disposed within the inner cavity 62 about the axis 58 and defines a generally concave spherical surface 92. The concave spherical surface 92 cooperates with the spherical surface 34 of the ball portion 24 to seat the ball portion 24 within the inner cavity 62 and allow rotation therein.

[0034] The cover plate 50 is generally annular in shape, having an outer periphery 110 and a central bore 114. The cover plate 50 has an outer portion 118 and an inner portion 120. The outer portion 118 extends radially outward from the inner portion 120 to the outer periphery 110 and may be generally flat or perpendicular to the axis 58, although other configurations may be used, such as slightly domed (e.g., conical or curved). The inner portion 120 defines the central bore 114. In the example provided, the inner portion 120 may be angled with the outer portion 118 such that the shape of the inner portion 120 may be slightly domed (e.g., conical or curved), protruding axially from the outer portion 118 to the central bore 114. The central bore 114 is threaded.

[0035] In the example provided, the lubricant fitting 54 is threaded into the central bore 114. The lubricant fitting 54 is configured to allow a lubricant (e.g., grease) to be selectively injected into the inner cavity 62. In the example provided, the lubricant fitting 54 is a grease nipple, but other configurations may be used. The biasing member 52 is disposed about the axis 58 and axially between the bearing 42 and the cover plate 50. In the example provided, the biasing member 52 is a Belleville washer that contacts the outer portion 118 of the cover plate 50 and the bearing 42, but other configurations may be used. The biasing member 52 axially biases the bearing 42 into contact with the ball portion 24.

[0036] Reference Figure 3-5 , the cover plate 50' is shown in a pre-installed state. The cover plate 50' is Figure 1 and Figure 2 The cover plate 50 is just Figure 1 and Figure 2 The cover plate 50 shown in is in an installed state. Therefore, like features are identified with like but primed reference numerals, and only the differences are described in detail herein. Prior to installation, the cover plate 50' is typically dome-shaped (e.g., conical or curved) such that the cover plate 50' has a concave side 124' and a convex side 126'. In the example provided, the cover plate 50' has a truncated conical shape such that the interior 120' and the exterior 118' form the same angle 128' relative to the central axis 58'. In one form, the angle 128' can be in the range of 30°-40°, such as 35°, but other angles or ranges of angles can also be used. In an alternative construction not specifically shown, the cover plate 50' may have a curved or arched dome shape.

[0037] Reference Figure 3-10 , illustrates and describes Figure 1 and Figure 2 The manufacturing method of the ball joint 10 in FIG. Figure 3-5 , the cover plate 50' is formed into a dome shape (e.g., a frustoconical shape). In the example provided, the cover plate 50' can be a metal material and can be stamped into a dome shape, but other methods of forming the cover plate 50' can also be used. The center hole 114' is then formed (e.g., drilled, punched, or cut) into the dome cover plate 50'. In an alternative construction, the center hole 114 can be formed into the cover plate 50' before being stamped into the dome shape. In the case where the cover plate 50' is dome-shaped, the center hole 114' is then tapped to form threads 132' therein.

[0038] Specific reference Figure 6, the rod member 14 is inserted into the first aperture 66 of the housing body 40 until the shaft portion 22 extends through the second aperture 70 and the ball portion 24 is seated on the ball seat 76. The bearing 42 is then positioned concentrically with the inner cavity 62 and inserted therein through the first aperture 66 until the bearing 42 is seated on the ball portion 24. The biasing member 52 is then positioned concentrically with the inner cavity 62 and inserted therein through the first aperture 66 until contact is made with the bearing 42.

[0039] When in the pre-installed state (i.e., dome shape with threaded center hole 114'), cover plate 50' is positioned concentric with inner cavity 62 and inserted into first aperture 66 such that periphery 110' is located on shoulder 86 and center hole 114' is axially outside of housing body 40. In this position, periphery 110' has a diameter less than the diameter of lip 90. Mold 210 is coaxially aligned with cover plate 50' and begins to move toward cover plate 50'.

[0040] In the example provided, the mold 210 includes an outer mold surface 214 and an inner mold surface 218, but other configurations may be used. The outer mold surface 214 is in contact with the installed cover plate 50 ( Figure 2 and Figure 8 )'s external 118( Figure 2 and Figure 8 ) coincides. In the example provided, the outer mold surface 214 is generally perpendicular to the axis 58 and is arranged in an annular shape around the axis 58, but the outer mold surface 214 does not need to be completely vertical. The diameter of the outer periphery 222 of the outer mold surface 214 is smaller than the diameter of the lip 90, so that the mold 210 can be received in the first orifice 66. The inner mold surface 218 is aligned with the installed cover plate 50 ( Figure 2 and Figure 8 ) inside 120( Fig.10 and Fig.12 ) coincides with and extends radially inward from the outer die surface 214. In the example provided, the inner die surface 218 extends radially inward at an angle 226 relative to the axis 58, such that the inner die surface 218 is concave and generally conical or frustoconical. In an alternative configuration not specifically shown, the inner die surface 218 may have a curved, concave shape.

[0041] The mold 210 moves axially in direction 230 (ie, toward the cover plate 50') until it contacts the cover plate 50' and then begins to axially compress the cover plate 50'. Figure 7 , the cover plate 50" is shown in a partially installed state, and its features are represented herein by the same but double-prime figure numbers. As the mold 210 continues to move axially in the direction 230, the cover plate 50" begins to deform (e.g., flatten) at a position close to the outer periphery 110". The deformation (e.g., flattening) causes the outer periphery 110" to expand radially outward into the annular groove 84 to secure the cover plate 50" to the shell body 40.

[0042] Reference Figure 8 , the mold 210 continues to move axially in the direction 230 and continues to deform (eg, flatten) at least the outer portion 118 of the cover plate 50 until the cover plate 50 is in the installed state as shown.

[0043] Reference Fig. 9 and Fig.10 , showing the thread 132' of the center hole 114' of the cover plate 50' in a pre-installed state and the thread 132 of the center hole 114 of the cover plate 50 in an installed state. The thread 132' is tapped with a tap (not shown) having a thread shape similar to that of the lubricant fitting 54 ( Figure 1-2 The thread shape of the thread 140 of the lubricant fitting 54 does not match and cannot be threadedly connected. The thread shape of the thread 132 in the installed state can be threadedly matched with the thread shape of the thread 140 of the lubricant fitting 54 ( Figure 1-2 In the example provided, the diameters of the threads 132' in the pre-installed condition (e.g., the major diameter 310', the minor diameter 314', and the pitch diameter 318' of the threads) are larger than the corresponding diameters of the threads 132 in the installed state (e.g., the major diameter 310, the minor diameter 314, and the pitch diameter 318 of the threads).

[0044] In the example provided, the thread 132' is a tapered thread shape in the pre-installed state such that it expands toward the top end 322' of the central hole 114'. Figure 6-8 The process of deforming (e.g., flattening) the cover plate 50, 50', 50" by the illustrated mold 210 causes the thread 132' to deform into a nearly straight thread or at least a tapered thread with a smaller taper when in the installed state. In an alternative configuration, the thread 132' may be a straight thread shape in the pre-installed state, and the thread 132 may maintain a straight thread shape and be reduced in diameter and / or deformed in other ways in the installed state.

[0045] In one configuration, the threads 132' are tapped in a pre-installed state with a thread size that is larger than the thread size of the threads 140 of the lubricant fitting ( Figure 1-2 In this regard, thread size refers to the nominal diameter of the thread form. For example, thread 132' may be tapped with a 5 / 16 inch (7.94 mm) tap, and lubricant fitting 54 ( Figure 1-2 ) can be a 1 / 4 inch (6.35 mm) thread form, but other sizes can also be used. Figure 6-8 The process of deforming (eg, flattening) the cover plates 50, 50', 50" by the die 210 shown in FIG. 1 causes the threads 132' to deform into contact with the lubricant fitting 54 ( Figure 1-2 ) have threads 140 of substantially the same thread size.

[0046] In another configuration, the threads 132' are in a pre-installed state to engage with the lubricant fitting 54 ( Figure 1-2 ) of the thread 140 are tapped with the same thread size, but with different fit grades. In this regard, the fit grade (also known as the tolerance grade or thread grade) refers to the acceptable range of pitch diameters. For example, the thread 132' can be tapped with a 5 / 16 inch (7.94 mm) tap, and the lubricant fitting 54 ( Figure 1-2 ) can be a 1 / 4 inch (6.35 mm) thread form, but other sizes can also be used. Figure 6-8 The process of deforming (eg, flattening) the cover plates 50, 50', 50" by the die 210 shown in FIG. 1 causes the threads 132' to deform into contact with the lubricant fitting 54 ( Figure 1-2 )'s thread 140 has approximately the same fit grade.

[0047] In yet another configuration, the size of the threads 132' (e.g., their minor diameter), and accordingly the size of the hole 114', is determined according to a predetermined equation that takes into account the material and geometry of the cover plate 50', the geometry of the annular groove 84, and the desired minor diameter of the threads 132. In one example, the above equation can be expressed as:

[0048]

[0049] In the example equation above, the desired path to start with is is the minor diameter of the thread 132' before deformation (by Figure 5 The reference numeral 134' in the figure indicates); the desired path is the desired minor diameter of the thread 132 after deformation; is the outer diameter of the cover before deformation ( Figure 5 T is the thickness of the cover plate 50' before deformation ( Figure 5 Indicated by reference symbol T); outer diameter of groove OD is the diameter of the annular groove 84 of the housing 40 into which the cover plate 50' deforms and constrains its outward deformation; C1, C2 and C3 are constants that take into account the characteristics of the material and / or geometry of the cover plate 50', such as taking into account the bending or change of the cross-sectional area of ​​the cover plate 50'; X A It is half of the cross-sectional area of ​​the cover plate 50' before deformation.

[0050] The values ​​of C1, C2, and C3 may vary with thickness and the initial angle 128' formed. For a cover plate 50' having a thickness T in the range of 1.78-3.81 mm (0.07-0.15 inches) and an initial angle 128' in the range of 30°-40°, these constants may be in the following ranges: C1: 1.27-25.4 mm (0.05-1 inch); C2: 25.4-76.2 mm (1-3 inches); C3: 11.43-19.05 mm (0.45-0.75 inches). It will be appreciated that C1, C2, and C3 for other thicknesses T and other initial angles 128' may have different constant values.

[0051] Since the cross-sectional area of ​​the cover plate 50' before deformation depends on the minor diameter 134' of the thread 132' before deformation, the method of calculating the thread size using the above equation may include: inputting a predicted value of the minor diameter 134', solving the equation, determining the error (e.g., % error) between the predicted value of the minor diameter 134' and the resulting value of the minor diameter 134' calculated based on the predicted value, and then iteratively adjusting the predicted value and recalculating the minor diameter 134' until the error is within a predetermined acceptable error. In one form, the iterative process can continue until the input predicted value of the minor diameter 134' is within a 10% error of the calculated value, but other error tolerances may also be used. Once the calculated minor diameter 134' is within an acceptable tolerance range, the thread 132' can be formed to have the calculated minor diameter 134'.

[0052] While the equation provided above is one example of an equation relating the material and geometry of the cover plate 50 ′, the geometry of the annular groove 84 , and the desired minor diameter of the threads 132 ′, other equations may be used to determine the size of the threads 132 ′ prior to deformation through a similar iterative process.

[0053] Reference Figure 11-13 , illustrates and describes the manufacturing Figure 1 and Figure 2 An alternative method of the ball joint 10. Figure 11-13 The method shown and described is similar to Figure 3-10 The method includes mold 210b including a pin or spindle 410. Mold 210b is otherwise similar to mold 210 ( Figure 6-8), and similar features are identified by the same numerals but with the suffix "b". The mandrel 410 is concentrically arranged with the center hole 114, 114', 114" and has an outer surface 414. The diameter of the outer surface 414 is equal to the desired minimum diameter of the thread 132 in the installed state. The desired minimum diameter can be smaller than the minimum diameter of the thread 132' in the pre-installed state. The mandrel 410 extends axially from the center of the mold 210b and extends into the center hole 114, 114', 114". The mandrel 410 controls or limits the radial inward deformation of the center hole 114', 114", 114 and the threads 132, 132', 132" during the pressing process.

[0054] Reference Fig.14 , shows a cover plate 50b' having another structure in a pre-installed state. The cover plate 50b' and the cover plate 50' ( Figure 3-5 ) unless otherwise shown or described herein. Therefore, similar features are identified with the same number but with the suffix "b", and only the differences are described in detail herein. In the example provided, the inner portion 120b' has a curved or arcuate shape or boss 510. The boss 510 is concave in the axial direction 230 and convex in the opposite axial direction 232. The inner portion 120b' is curved from the outer portion 118b' in a concave manner to the central hole 114b' on the concave side 124b', and is curved from the outer portion 118b' in a convex manner to the central hole 114b' on the convex side 126b'.

[0055] Reference Fig.15 The method of installing the cover plates 50b', 50b is similar to that of referring to Figure 3-10 The method shown and described is the same, except that mold 210c is used in place of mold 210 or 210b. Mold 210c is similar to mold 210 or 210b unless otherwise shown or described herein. Therefore, similar features are identified with the same numbers but with the suffix "c", and only the differences are described in detail herein. In the example provided, the inner mold surface 218c is curved or arcuate to match the interior 120b of the cover plate 50b. The curved or arcuate interior 120b and inner mold surface 218c can result in reduced deformation of the center hole 114b and result in the cover plate 50b having a boss 510 in the installed state. Although not specifically shown, the mold 210c can optionally include a spindle similar to the spindle 410 ( Figure 11-13 )'s main axis.

[0056] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged to, connected to, or coupled to the other element or layer. There may be other elements or layers, or intervening elements or layers. Conversely, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers. Other words used to describe relationships between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0057] Although the terms first, second, third, etc. can be used to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited to these terms. These terms can only be used to distinguish an element, component, region, layer and / or part from another element, component, region, layer and / or part. Terms such as "first", "second" and other numerical terms do not imply order or sequence when used in this article unless the context clearly indicates. Therefore, the first element, component, region, layer or part can be referred to as the second element, component, region, layer or part, without departing from the teaching of the example form. In addition, an element, component, region, layer or part can be referred to as a "second" element, component, region, layer or part, without the need for an element, component, region, layer or part to be referred to as a "first" element, component, region, layer or part.

[0058] Spatially relative terms such as "inside", "outside", "below", "under", "lower", "above", "upper", etc. may be used herein for ease of description to describe the relationship of one element or feature to another element or feature, as shown in the figures. In addition to the orientation depicted in the figures, spatially relative terms may be intended to cover different orientations of the device in use or operation. For example, if the device in the figure is flipped, an element described as being "below" or "below" other elements or features will be oriented as being "above" the other elements or features. Therefore, the exemplary term "below" may cover the orientation above or below. The device may be oriented in other ways (rotated 90 degrees or in other orientations) and the spatially relative descriptors used herein are interpreted accordingly.

[0059] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical or, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

[0060] Unless otherwise expressly stated, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances or other characteristics should be understood to be in accordance with the present disclosure. Such modifications are required for a variety of reasons, including industrial practice, manufacturing techniques, and testing capabilities.

[0061] The terms used herein are only for the purpose of describing specific example forms and are not intended to be limiting. The singular forms "a", "an" and "the" may also be intended to include plural forms unless the context clearly states otherwise. The terms "including" and "having" are inclusive, and therefore specify the presence of the features, wholes, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components and / or their groups. The method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the particular order discussed or illustrated, unless specifically identified as an execution order. It should also be understood that additional or alternative steps may be adopted.

[0062] The description of the present application is merely exemplary in nature, and therefore, examples that do not depart from the essence of the present application are intended to fall within the scope of the present application. Such examples should not be considered as departing from the spirit and scope of the present application. The broad teachings of the present application can be implemented in various forms. Therefore, although the present application includes specific examples, the true scope of the present application should not be so limited, because other modifications will become apparent after studying the drawings, description and appended claims.

Claims

1. A method of manufacturing a vehicle suspension component, the method comprising: inserting a rod of the vehicle suspension assembly into a housing of the vehicle suspension assembly such that a ball portion disposed at a first end of the rod is located within the housing and is rotatable relative to the housing, and a second end of the rod extends from the housing; inserting a cover of the housing into an aperture of the housing defined in a first end of the housing, the cover defining a threaded hole of a first diameter; as well as pressing the mold against the cover to deform the cover so that the periphery of the cover is deformed to remain engaged with the housing and the threads of the threaded hole are at least partially deformed, The deformation of the cover body causes the threaded hole to deform, thereby reducing the first diameter of the threaded hole from a pre-deformed state of the cover body. 2 . The method of claim 1 , further comprising inserting a bearing of the housing into the aperture defined in the first end of the housing such that the bearing is seated on the ball portion.

3. The method of claim 1 , wherein the cover is disposed about a central axis concentric with the orifice of the shell defined in the first end of the shell, the cover having a convex side and a concave side, the threaded hole being concentric with the central axis, and wherein deforming the cover comprises pressing against the convex side until the threaded hole is at least partially deformed and the outer circumference of the cover is enlarged compared to a pre-deformed state of the cover. The method of claim 1 , further comprising threading a fitting into the threaded hole.

5. The method according to claim 4, wherein: The accessory is a grease nipple.

6. The method according to claim 1, wherein: Deforming the cover includes deforming the outer periphery of the cover radially outward into a recess defined by the housing.

7. The method of claim 1, further comprising inserting a pin of the mold into the threaded hole, and wherein, When the pin is disposed within the threaded hole, the cover is deformed to maintain engagement with the housing.

8. The method according to claim 7, wherein: The diameter of the pin is equal to a required minimum thread diameter, which is smaller than the minimum thread diameter of the threaded hole in the pre-deformed state of the cover body.

9. The method of claim 1 further includes producing the cover, including tapping the threaded hole using a tap having a first thread size and an initial fit grade, and the method further includes screwing an accessory into the threaded hole after deforming the cover to retain engagement with the housing, the thread of the accessory having the first thread size and a fit grade different from the initial fit grade.

10. The method of claim 1 further comprising producing the cover, comprising tapping the threaded hole using a tap having an initial thread size, and the method further comprising screwing an accessory into the threaded hole after deforming the cover to retain engagement with the housing, the thread of the accessory having a thread size smaller than the initial thread size.

11. The method of claim 1 , further comprising producing the cover, comprising tapping the threaded hole with a tapered thread, and wherein, Deforming the cover includes deforming the threaded hole to reduce the taper of the tapered threads.

12. The method according to claim 1, wherein: The cover is deformed to remain engaged with the housing by pressing a mold against the convex side of the cover, the mold having an outer mold portion and an inner mold portion, the outer mold portion engaging the exterior of the cover and the inner mold portion engaging the interior of the cover.

13. The method according to claim 1, wherein: The threaded hole is disposed in a boss defined by the cover body after the cover body is deformed.

14. The method of claim 1, wherein the rod is inserted into the housing through the aperture of the housing defined in the first end of the housing.

Images