Rotary joint, related assembly and method of manufacturing same

Abstract

A rotary joint and a method of manufacturing a rotary joint are provided. The rotary joint includes a housing having an outer mounting surface and an inner housing member defining an inner chamber having an inner surface forming a spherical section symmetrical about a center point. The stud has a longitudinal axis passing through a center point and a proximal end having a surface defining a spherical section that matches an interior surface of the at least one inner housing member. The proximal end allows the stud to rotate about its longitudinal axis. A closure member secures the proximal end within the housing. The closure member includes a non-right angle side positioned between an outer surface and a side surface of the closure member. The lip of the housing adjoins the side surface and includes a stack coupled to the non-right-angle side for securing the proximal end within the interior chamber.

Description

[0001] Cross - reference to related applications and priority applications This application claims priority to U.S. Patent Application No. 17 / 963,701, filed on October 11, 2022, the entire content of which is incorporated herein by reference. Technical Field

[0002] The present disclosure generally relates to automotive rotary joints, and more particularly, to a cover of a housing of an automotive rotary joint. Background Art

[0003] A rotary joint (such as a ball joint) may include a laminate to couple components of the rotary joint together. In the embodiment shown in FIG. 1A (a cross - sectional view of a rotary joint 1 shown as a ball joint), a laminate 13' with a housing lip is on a closure plate 8' (also referred to in this application as a "closure member", "cover end", or "back plate"). Laminating the lip of the rotary joint housing onto the cover end can keep the internal components (i.e., the cover end 8', the spherical portion 15' of the stud 14', and the protective shield 17') in place within the internal cavity of the housing. As shown in FIGS. 1A and 1B, the laminate 13' extends above the right - angled straight edge 12' of the cover end 8'. The surface area of the right - angled straight edge 12' extending along the vector defined by the edge 12' is small, which provides a small coupling area between the laminate 13' and the cover end 8'. There is also little contact between the side surface 11' of the cover end 8' and the laminate 13'. Specifically, it is the junction between the laminate 13' and the external cover end surface 10' that keeps the internal components of the rotary joint in place. However, during the manufacturing process, as the laminate 13' is bent onto the right - angled edge 12' of the cover end 8', the laminate 12' may only contact the marginal surface of the cover end on the side surface 11' or the external surface 10' of the cover end. As a result, the cover end 8' may be misaligned or move during the use of the rotary joint 1', causing wear of the cover end 8' and the internal components of the rotary joint 1', thus shortening the service life of the rotary joint.

[0004] The features that distinguish the present invention from the background art will be apparent from the following disclosure, drawings, and description of the present invention. Summary of the Invention

[0005] In one aspect, the present disclosure describes a rotary joint that includes: a housing that includes: an external mounting surface for coupling to a component; at least one internal housing member that defines an internal chamber having an internal surface that forms a spherical segment symmetric about a central point; a stud that has: a longitudinal axis passing through the central point, a proximal end that has a surface defining the spherical segment, the surface of the proximal end matches the internal surface of the at least one internal housing member, the proximal end is configured to allow the stud to rotate about its longitudinal axis and optionally swing out an angle relative to the central point; a closure member for fastening the proximal end within the housing, the closure member includes a non-right angled edge positioned between the external surface and the side surface of the closure member; a lip that is positioned adjacent to the side surface on the housing, the lip includes a laminate coupled to the non-right angled edge for fastening the proximal end within the internal chamber.

[0006] In some embodiments, the internal housing member includes an inner ring.

[0007] In some embodiments, the closure member is a plate that defines a hole opposite a bottom end, the external surface is opposite the bottom end of the housing, and the stud extends through the hole.

[0008] In some embodiments, the non-right angled edge includes an angled surface that has a tangent at a first angle relative to a first plane and at a second angle relative to a second plane, the first plane is defined by a first tangent of the external closure member surface, and the second plane is defined by a second tangent of the side surface. The first angle or the second angle can be in the range of 1 - 45 degrees, can be in the range of 10 - 30 degrees, or can be about 20 degrees. The angled surface of the non-right angled edge can have a length of 0.5 - 2 mm, 0.8 - 1.5 mm, or greater than 1 mm. Along the length of the laminate, the laminate can have a thickness greater than 0.7 mm, in the range of 1.4 - 2.3 mm, and / or in the range of 1.4 - 1.7 mm. Along the length of the laminate, the laminate can have a generally uniform thickness. The laminate can have a tapered cross-section. The depth of the lip can be in the range of 5 mm to 10 mm, and / or in the range of 5.5 mm to 7 mm.

[0009] In some embodiments, the non-right angled edge includes one of an arcuate curve, a rounded edge, a chamfered edge, or a beveled edge.

[0010] In some embodiments, the lip is coupled to the non-right angled edge, the external closure member surface, and the side surface.

[0011] In some embodiments, the component is a control arm, a tie rod, or a stabilizer bar.

[0012] Embodiments can include combinations of the above features.

[0013] In another aspect, the present disclosure describes a method including: providing a housing including: an external mounting surface for coupling to a component; an internal chamber having an internal surface forming a spherical segment symmetric about a central point; and a lip defining a hole; positioning a stud within the internal chamber, the stud having: a longitudinal axis passing through the central point, a proximal end having a surface defining the spherical segment, the surface of the proximal end matching the internal surface of at least one internal housing member, the proximal end being configured to allow the stud to rotate about its longitudinal axis and optionally swing out of angle relative to the central point; positioning a closure member within the housing to secure the proximal end within the housing, the closure member including a non-rectangular edge positioned between an external surface and a side surface of the closure member; and laterally positioning the lip adjacent and contiguous to the closure member, the lip extending away from a plane defined by the external closure member surface; laminating the lip to the non-rectangular edge of the closure member to form a laminate.

[0014] In some embodiments, laminating the lip includes pressing a die face of a die into the lip, the die face defining a plane positioned at a die angle relative to the longitudinal axis of the housing; and pressing the lip against the non-rectangular edge to form a laminate having a length and a thickness. The die can be a rotary die, and laminating the lip can include: rotating the die or the housing about the longitudinal axis of the housing at a rotational speed; and feeding the die towards the lip at a feed rate. The die angle can be at least one of the following: in the range of 45 - 70 degrees, and / or about 61.5 degrees. The rotational speed can be at least one of the following: in the range of 100 - 200 rpm, and / or about 150 rpm. The feed rate can be in the range of 0.01 mm / s to 0.5 mm / s, preferably about 0.2 mm / s.

[0015] In some embodiments, along the length of the laminate, the laminate has a thickness that is at least one of the following: greater than 0.7 mm, in the range of 1.4 - 2.2, and / or in the range of 1.4 - 1.7 mm.

[0016] In some embodiments, along the length of the laminate, the laminate has a substantially uniform thickness.

[0017] In some embodiments, the laminate has a tapered cross-section.

[0018] In some embodiments, the lip has a depth that is at least one of the following: in the range of 5 mm to 10 mm, and / or in the range of 5.5 mm to 7 mm.

[0019] In some embodiments, the non-right-angle side includes an angled surface having a tangent that forms a first angle with respect to a first plane and a second angle with respect to a second plane, where the first plane is defined by a first tangent of the outer closure member surface and the second plane is defined by a second tangent of the side surface. The first angle or the second angle can be: in the range of 1 - 45 degrees, in the range of 10 - 30 degrees, or approximately 20 degrees.

[0020] In some embodiments, the non-right-angle side includes one of an arcuate curve, a rounded edge, a chamfered edge, or a beveled edge.

[0021] In some embodiments, the laminate is coupled to the non-right-angle side, the outer closure member surface of the closure member, and the side surface.

[0022] Embodiments can include combinations of the above features.

[0023] In a further aspect, the present disclosure describes a mechanical assembly that includes: a suspension member or a steering member coupled to a swivel joint, the swivel joint including: a housing having: an outer mounting surface for coupling to a component; at least one internal housing member defining an internal chamber having an internal surface that forms a spherical segment symmetric about a center point; a stud having: a longitudinal axis passing through the center point, a proximal end having a surface that defines the spherical segment, the surface of the proximal end mating with the internal surface of the at least one internal housing member, the proximal end being configured to allow the stud to rotate about its longitudinal axis and optionally swing out of angle with respect to the center point; a closure member for fastening the proximal end within the housing, the closure member including a non-right-angle side positioned between the outer surface and the side surface of the closure member; a lip positioned on the housing adjacent to the side surface, the lip including a laminate coupled to the non-right-angle side for fastening the proximal end within the internal chamber.

[0024] Embodiments can include combinations of the above features.

[0025] These and other aspects of the subject matter of this application will become apparent from the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Reference is now made to the accompanying drawings, in which: FIG. 1A shows a cross-sectional view of the above-described prior art assembly, and FIG. 1B is a fragmentary view of FIG. 1A showing the laminate and the closure plate of the prior art assembly; Figure 2A is a perspective view of an exemplary swivel joint according to the present disclosure; Figure 2B is Figure 2A a cross-sectional view of an embodiment of the exemplary swivel joint taken along line A - A; Figure 2C is Figure 2A Another embodiment of an exemplary swivel joint in the [embodiment] is a sectional view along line A-A; Figure 5 shows a perspective view of a control arm of a swivel joint including Figure 2A ; Figure 3 shows Figure 2B a partial view of detail D1, which shows a non-right-angled side; Figure 4A and Figure 4B shows a sectional view of an exemplary closure member having a non-right-angled side; Figure 6 shows a schematic flow chart which shows an exemplary method of manufacturing a swivel joint according to the present disclosure; Figure 7A shows a sectional view of an exemplary housing of an exemplary swivel joint according to the present disclosure before rotational molding lamination; Figure 7B shows a sectional view of an exemplary housing of an exemplary swivel joint according to the present disclosure after rotational molding lamination; Figure 8 shows a sectional view of an exemplary test fixture for testing the lamination to the closure member; Figure 9A shows a finite element analysis model simulating stress when a force is applied to a closure member having a right-angled side, wherein the right-angled side is coupled to the lamination; and, Figure 9B shows a finite element analysis model simulating stress when a force is applied to a closure member having a non-right-angled side, wherein the non-right-angled side is coupled to the lamination; Figure 10 shows a test data graph comparing the pullout load and displacement of the closure member. DETAILED DESCRIPTION

[0027] The following disclosure relates to swivel joints for motor vehicles. In one aspect, there are provided swivel joints for powertrain, steering components, and suspension components of motor vehicles, and related methods of manufacturing swivel joints. In some embodiments, the disclosed swivel joint includes a spherical stud, wherein the spherical portion of the spherical stud is fastened within a housing by an end cap having a non-right-angled side so as to achieve better stress distribution when laminating the housing to the non-right-angled side.

[0028] Although terms such as "maximize", "minimize", and "optimize" may be used in the present disclosure, it should be understood that such terms may be used to refer to improvement, adjustment, and refinement, and not strictly limited to maximum, minimum, or optimal.

[0029] The terms "connected" or "coupled to" may include direct coupling (where two elements that are mutually coupled are in contact with each other) and indirect coupling (where at least one additional element is located between the two elements).

[0030] As used in this application, the term "substantially" may be used to modify any quantitative description that can be permissibly varied without changing its associated basic function.

[0031] Terms such as "at most", "at least", "greater than", "less than", "more than", or "or more" include the recited numbers, and the ranges indicated by such terms may then be divided into sub-ranges. Similarly, all ratios recited in this application also include all sub-ratios that fall within a broader range.

[0032] Unless the context clearly dictates otherwise, the singular forms of "a", "an", and "the" include plural meanings. The term "and / or" means any one of the items associated with this term, any combination of the items, or all of the items.

[0033] The term "about" may refer to a range of variation of ±5%, ±10%, ±20%, or ±25% of the specified value. For example, "about 50%" may represent a range of variation from 45% to 55% in some embodiments. For integer ranges, the term "about" may include one or two integers greater than and / or less than the recited integer at each end of the range. Unless otherwise stated in this application, the term "about" is intended to include values and ranges that are close to and functionally equivalent to the recited range.

[0034] As used in this application, the term "lamination" may refer to the portion of the housing that covers the enclosed member as described in this application. The covering portion may cause the materials of the housing and the enclosed member to bond by pressure to fasten the housing and the enclosed member stationary relative to each other. Similarly, the term "laminating" may refer to the process of covering a portion of the housing onto the enclosed member as described in this application to fasten the housing and the enclosed member stationary relative to each other.

[0035] Aspects of various embodiments are described with reference to the accompanying drawings.

[0036] Figure 2A An exemplary rotary joint 1 according to the present disclosure is shown. Figure 2B The rotary joint 1 is shown along Figure 2ACross-sectional view of line A-A. The rotary joint 1 is shown as a spherical joint, but can be any other type of rotary joint. As shown, the rotary joint 1 includes a stud 14 having a proximal end 14A received within a housing 2. The proximal end 14A of the stud 14 can have an outer surface defining a spherical section S-S and can be coupled to an inner housing member 5 that forms a socket for receiving the proximal end 14A. The distal end 14B of the stud 14 can extend through a hole 511 defined by the housing 2 for coupling to a component (not shown) of an automobile. In an embodiment, the proximal end 14A can be the spherical portion of a spherical stud and can allow the stud 14 to rotate about its longitudinal axis Φ and / or allow the stud 14 to pivot about a center point relative to its longitudinal axis Φ at an angle γ. The proximal end 14A can have various sizes. In a non-limiting embodiment, the proximal end 14A defines a spherical section S-S with a diameter of 25 mm, 30 mm, or 35 mm. The housing 2 can have an inner housing member 5 defining an inner chamber having a generally spherical inner surface 5A that is symmetric about a center point 6. The inner housing member 5 (such as an inner ring and / or bearing) can define the inner chamber. The inner surface of the inner chamber can be configured to abut and define the surface of the proximal end 14A. The inner chamber can include a bottom end 7, and a closure member 8 as Figure 2B shown is opposite the bottom end 7, presenting a closed top design.

[0037] As Figure 2B shown, the closure member 8 can have a hole 9 opposite the bottom end 7 through which the stud 14 projects from the housing 2, and Figure 3 the shown outer closure member surface 10 and side surface 11 can be coupled to a laminate 13 for fastening the proximal end 14A within the housing 2. The side surface 11 of the closure member 8 can be positioned towards the inner surface of the housing 2 and / or positioned along a radial line extending from the longitudinal axis λ in a direction perpendicular to the longitudinal axis λ of the housing 2. The outer closure member surface 10 can be positioned in a direction parallel to the longitudinal axis λ. In some embodiments, the rotary joint 1 can be a closed bottom design as Figure 2C shown. The closure member 8 can be positioned at the bottom end opposite the hole 551 through which the stud 14 extends. Figure 2B And Figure 2C the closure members 8 of Figure 3 can each include Figure 3As shown, the non-right-angled side 12 is between the outer closed member surface 10 and the side surface 11. The proximal end 14A can be fastened in place within the housing 2 by the laminate 13, which couples the housing 2 to the non-right-angled side 12, the side surface 11, and / or the outer closed member surface 10. The proximal end 14A and the stud 14 can rotate freely within the housing 2 about the longitudinal axis Φ, or can pivot freely at an angle γ relative to the central point 6.

[0038] Figure 3 As shown Figure 2B is a partial view of the detail D1, which shows the non-right-angled side 12. Although Figure 3 shows a top-closed design, the closed member 8 with the non-right-angled side 12 described in the present application can also be used for a bottom-closed design. For example, Figure 2C the detail D2 shows the non-right-angled side, which can have the same arrangement as the arrangement described with reference to the detail D1 in the present application. The non-right-angled side 12 can include an angled surface having a tangent that defines a plane C at an angle α with respect to a plane B, where the plane B is defined by the tangent of the outer cover end surface 10. The angled surface of the non-right-angled side 12 can also have a tangent that defines a plane C at a second angle β with respect to a plane A, where the plane A is defined by the tangent of the side surface 11. In an embodiment, both the angles α and β can be in the range of 1 - 45 degrees. In another embodiment, both the angles α and β can be in the range of 10 - 30 degrees. In another embodiment, both the angles α and β can be approximately 20 degrees. In some embodiments, the non-right-angled side 12 is an arcuate curve, a rounded edge, a chamfered edge, or a beveled edge. Figure 4A shows a cross-sectional view of an exemplary closed member shown as a plate, where the plate has a non-right-angled side 12a with a substantially arcuate curve having a radius R1. In some embodiments, the radius R1 can be in the range of 0.5 - 2 mm. In an example, R1 can be approximately 1 mm or 1.5 mm. Figure 4B shows a cross-sectional view of another exemplary closed plate having a non-right-angled side 12b. As Figure 4B shown, the non-right-angled side 12b can include an angled surface having a tangent that defines a plane C at an angle α of approximately 30 - 45 degrees. The cross-sectional length L, i.e., the length of the non-right-angled side as viewed in a plan view, can be in the range of 0.1 mm to 10 mm. In an example, the cross-sectional length L is approximately 0.5 - 1 mm. Compared with a right-angled side, the non-right-angled side can allow the stress acting on the rotary joint to be dispersed over a larger surface area defined by the non-right-angled side 12, which improves durability and reduces the fracture condition under stress compared to the exemplary rotary joint 1' shown in FIG. 1A.

[0039] The length of the non-right-angled side 12 can vary according to the size and design of the rotary joint. The length of the non-right-angled side 12 can be the distance along the surface of the non-right-angled side 12 between the edge of the side surface 11 and the edge of the outer cover end surface 10. The non-right-angled side 12 can include a plurality of surfaces or rounded corners, for example, to define a generally arcuate shoulder. Thus, the length of the non-right-angled side 12 can be the distance along the surface of the non-right-angled side 12 between the edge of the side surface 11 and the edge of the outer cover end surface 10 passing through a plurality of surfaces or rounded corners. Therefore, the area defined by the non-right-angled side 12 can be defined by the length and circumference of the closure member. In an embodiment, the non-right-angled side has a length of 0.5 - 2 mm. In another embodiment, the length can be 0.8 - 1.5 mm. In another embodiment, the length can be greater than 1 mm. The laminate 13 that couples the housing 2 to the non-right-angled side 12 can have a variable thickness T along its length, or as Figure 3 shown, have a generally uniform thickness T along its length. In an embodiment, the laminate 13 has a tapered cross-section as Figure 3 shown. Some embodiments can have a laminate thickness greater than 0.7 mm, in the range of 1.4 - 2.3 mm, or in the range of 1.4 - 1.7 mm. The length of the laminate 13 generally corresponds to the depth D of the lip of the housing as Figure 7A shown. The length of the laminate 13 can vary such that the laminate 13 extends not only to the non-right-angled side 12 but also to the outer cover end surface 10. In an embodiment, the depth of the lip can be between 5 - 10 mm, or in the range of 5.5 - 7 mm. As Figure 7A shown, the depth D of the lip 510 can be the distance between the distal tip of the lip and the proximal end of the lip 510 (intersecting the plane B defined by the outer surface of the closure member).

[0040] The housing 2 can include an outer mounting surface 3 for coupling to at least one external component 4 (such as Figure 5 the control arm shown) and other components (not shown) to allow relative rotational movement between the external component 4 and the other components. In some embodiments, the rotary joint 1 described in the present application can be coupled to a suspension member or a steering member to form a mechanical assembly. For example, the mechanical assembly can be formed by coupling the rotary joint 1 to the component 4. In some embodiments, the component 4 can be a control arm, a stabilizer bar, or a tie rod.

[0041] Referring to Figure 6 the method 600 shown in the flowchart describes a method of manufacturing a rotary joint according to the present disclosure. Figure 7A and Figure 7B further shows an illustration of an embodiment of the method 600.

[0042] At 602, the housing (such asFigure 7A The housing 2) shown can be provided with an external mounting surface 3 for coupling to a component. The housing 2 can include at least one internal housing member that defines an internal chamber having an internal surface 5 that forms a spherical segment symmetric about a central point 6. The housing 2 can include a lip 510 that defines a hole 511 through which a closure member 8 can be positioned.

[0043] At 604, a stud (shown in Figure 2B and Figure 2C but not shown in Figure 7A and Figure 7B for simplicity of the drawing) can be positioned within the internal chamber. The stud 14 can have a longitudinal axis passing through the center point of the proximal end 14A of the stud, and the proximal end can have a surface that defines a spherical segment S - S as shown in Figure 2B and Figure 2C . The surface of the proximal end 14A can have an outer surface that matches the internal surface of at least one internal housing member, wherein the proximal end is configured to allow the stud to rotate about its longitudinal axis and optionally swing out an angle relative to the central point.

[0044] At 606, the closure member 8 can also be positioned within the housing to fasten at least one internal housing member and / or the proximal end 14A of the stud 14 within the housing 2. The closure member 8 includes a non - right - angled edge located between the outer surface 10 and the side surface 11 of the closure member. The outer surface 10 can be positioned in a direction parallel to the longitudinal axis λ of the housing 2. For example, the outer surface 10 can have a tangent perpendicular to the longitudinal axis λ of the housing and be positioned away from the internal surface of the housing 2, as shown in Figure 7A . The side surface 11 can be positioned adjacent and contiguous to the lip 510 of the housing 2 and / or positioned along a radial line from the longitudinal axis λ in a direction perpendicular to the longitudinal axis λ towards the lip 510.

[0045] At 608, the lip 510 of the housing 2 can be set adjacent and / or contiguous to the side surface 11. The lip 510 can extend away from the plane B defined by the tangent of the outer closure member surface 10.

[0046] At 610, the lip 510 can be laminated to the non - right - angled edge 12 of the closure member 8 to form a laminate 13. The closure member 8 can define a hole through which the stud can extend, and the closure member can be positioned opposite the bottom end of the housing 2 such that the housing 2 is top - closed. In another embodiment, the housing can be bottom - closed, where the closure member 8 is positioned opposite the hole 511 to form the bottom end of the housing 2. As shown in Figure 7A , a rotary die 16 can rotate about the outer periphery of the housing 2 and the longitudinal axis λ of the housing. As the die 16 feeds towards the lip 510 at a feed rate v, to asFigure 7A As shown, the lip 13 is laminated against the non-rectangular side 12 to form a laminate 13 as Figure 7B shown. The die 16 may have a surface at a roller angle θ with respect to the longitudinal axis λ. In some embodiments, the angle θ of the die 16 may be in the range of 45 - 70 degrees. In a particular embodiment, the angle θ may be approximately 61.5 degrees.

[0047] In an embodiment, the feed rate v may be configured to provide a consistent laminate while minimizing the stress applied to the lip 510. In some embodiments, the feed rate v may be in the range of 100 - 200 rpm. In other embodiments, the feed rate v may be approximately 150 rpm, 0.01 - 0.05 mm / s, or 0.2 mm / s. The feed rate may vary according to the metal properties of the housing 2 and the length, thickness, and shape of the lip 510.

[0048] In an embodiment, before laminating the closure member 8 to the housing 2, the closure member 8 may be separate and uncoupled from the housing 2, where the housing 2 defines a hole 511 through which the proximal end 14A of the inner housing member 5 and / or the stud 14 may be inserted and positioned within the housing 2. Subsequently, the closure member 8 may be positioned to fasten the proximal end 14A of the inner housing member 5 and / or the stud 14 within the housing 2 and laminated through the lip 510 to couple the closure member 8 to the housing 2. Embodiment

[0049] The strength of an exemplary laminate according to the present disclosure is evaluated to determine its ability to withstand a pull-out force. A stress analysis is also performed on the rotary joint.

[0050] The exemplary laminate is tested using a fabricated test fixture 20 that includes a cover plate 17 and a rod 18a configured to be inserted into the housing 21 to Figure 8 abut against and apply pressure to the cover plate 17 within the housing 21 as shown, thereby pushing on the laminate 23 of the housing 21.

[0051] For different sphere sizes of 25, 30, and 35 mm, housing blanks are fabricated with different structural characteristics and different manufacturing methods. The rod 18 is inserted into each blank housing, and the rod size is matched to the size of the housing blank.

[0052] Each push-out test is performed on the laminated housing assembly using a test fixture as Figure 8 shown, where the member 22 applies a force to the rod 18 until the laminate 23 fails, i.e., the cover plate 17 is pushed out of the housing 21 by deforming the laminate 23. The force required to fail the laminate 23 is measured and recorded.

[0053] The height of the laminated lip and the size of the sphere are varied in various tests. All parameters and stress profiles are recorded to evaluate the laminated strength measured by the push-out load. In one test - with a sphere size of 25 mm and a laminated lip thickness ( Figure 3 T in

[0054] of 1.5 mm), when the height of the laminated lip is 5.5 mm, the minimum push-out load is 57.39 KN, and when the height of the laminated lip is 7.5 mm, the highest tested push-out load is 85.14 KN.

[0055] Figure 9A A finite element analysis model of a simulated pull-out test on a spherical joint is shown, where the spherical joint has a right-angled edge at the cover end. Figure 9B A finite element analysis model of the same pull-out test on a laminated structure with a non-right-angled edge is shown. Specifically, the non-right-angled edge is a chamfered edge at an angle of approximately 45° to the adjacent outer cover end surface and side surface of the enclosed member, where all other variables are kept constant. As Figure 9B shown, compared with using a right-angled edge as shown in, for example, FIGS. 1A and 1B Figure 9A the maximum stress experienced by the laminated lip is significantly reduced when using a non-right-angled edge. In the simulation, a force of 65 KN is applied to each of the end plates shown in Figure 9A and Figure 9B . As a result, compared with the stress experienced by the end plates and the laminate in Figure 9A using a right-angled edge, the stress along the length of the enclosed member and in the laminate in Figure 9B is reduced. Specifically, the maximum von mises stress recorded on the laminate in Figure 9A is 470 MPA, while for the laminate with a non-right-angled edge in Figure 9BThe maximum von Mises stress recorded on the laminate is 370 MPA. The non-right-angle side 12 allows the force applied to the laminate via the cover end to be distributed along the surface of the non-right-angle side and the opposite laminate surface, rather than at the right-angle side that forms a narrow fracture point (where the force applied to the cover end would concentrate). Compared with similar rotary joints using right-angle cover ends, this can improve the anti-deformation ability of the laminate during use, enhance the laminate strength and durability over time, and extend the service life of the rotary joint. Figure 10 shows a test data graph comparing the pull-out load and displacement of the closure member. For Figure 10 the test data presented, two samples of top-closed spherical joints with the same design were prepared: one with a cover end having a non-right-angle side and the other with a cover end having a right-angle side. Specifically, the non-right-angle side is a chamfered edge that forms an angle of approximately 45° with the adjacent outer cover-end surface and the side surface of the cover end, with all other variables remaining the same. The samples have a laminate with a thickness of 1.5 mm and a ball of a spherical stud with a diameter of 35 mm. A measured force is applied to the cover end, and the stud of each spherical joint is pulled. The displacement of the cover end relative to its original position is also recorded and plotted in Figure 10 . As Figure 10 shown, the two curves show that for both the right-angle side embodiment and the non-right-angle side embodiment, as the stud is pulled, the force applied to the cover end causes the cover end to displace, resulting in laminate deformation. However, a greater load is required to displace the cover end with a non-right-angle side compared to the cover end with a right-angle side. For example, at an applied load of 20 KN, the cover end with a non-right-angle side displaces approximately 1 mm less than the cover end with a right-angle side. As shown in the figure, the slope of each curve indicates that for the same applied load, the non-right-angle side has a smaller displacement than the right-angle side embodiment. In other words, due to the higher slope of the non-right-angle side, the closure member with a non-right-angle side can provide greater resistance to the deformation of the laminate on the non-right-angle side. In this way, the non-right-angle side can reduce edge stress and improve the durability and lifespan of the rotary joint and the components coupled thereto.

[0056] Alternative embodiments The above description is merely exemplary, and those skilled in the relevant art will recognize that changes can be made to the described embodiments without departing from the scope of the disclosed invention. Without departing from the subject matter of the claims, the present disclosure can be embodied in other specific forms. The present disclosure is intended to cover and include all suitable changes in technical aspects. Based on a review of the present disclosure, modifications that fall within the scope of the present invention will be obvious to those skilled in the art, and such modifications should be considered to fall within the scope of the appended claims. In addition, the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the overall description.

[0057] It is understood that the detailed embodiments described and shown above are intended only as examples. The present invention is defined by the appended claims.

[0058] A claim does not include, and should not be construed as including, a means-plus-function or step-plus-function limitation, unless such a limitation is expressly recited in a given claim using the recitation "means for" or "step for".

Claims

1. A rotary joint, the rotary joint comprising: a housing, the housing comprising: an external mounting surface for coupling to a component; at least one internal housing member defining an internal chamber having an internal surface that forms a spherical segment symmetric about a central point; a stud having a longitudinal axis passing through the central point, a proximal end having a surface defining a spherical segment, the surface of the proximal end mating with the internal surface of the at least one internal housing member, the proximal end being configured to allow the stud to rotate about its longitudinal axis and optionally swing out an angle relative to the central point; a closure member for securing the proximal end within the housing, the closure member including a non-right angled edge positioned between an external surface and a side surface of the closure member; a lip positioned adjacent to the side surface on the housing, the lip including a laminate coupled to the non-right angled edge for securing the proximal end within the internal chamber.

2. The rotary joint according to claim 1, wherein, the closure member is a plate defining a hole opposite a bottom end, the external surface being opposite the bottom end of the housing, and the stud extending through the hole.

3. The rotary joint according to claim 1, wherein, the non-right angled edge includes an angled surface having a tangent at a first angle relative to a first plane and at a second angle relative to a second plane, the first plane being defined by a first tangent of the external closure member surface and the second plane being defined by a second tangent of the side surface.

4. The rotary joint according to claim 3, wherein, the first angle or the second angle is in the range of 1 - 45 degrees, in the range of 10 - 30 degrees, or is about 20 degrees.

5. The rotary joint according to claim 3, wherein, the angled surface of the non-right angled edge has a length of 0.5 - 2 mm, 0.8 - 1.5 mm, or greater than 1 mm.

6. The rotary joint according to claim 1, wherein, the laminate has a generally uniform thickness along the length of the laminate; a tapered cross-section; or a thickness along the length of the laminate that is greater than 0.7 mm, in the range of 1.4 - 2.3, and / or in the range of 1.4 - 1.7 mm.

7. The rotary joint according to claim 1, wherein, the depth of the lip is in the range of 5 mm to 10 mm, and / or in the range of 5.5 mm to 7 mm.

8. The rotary joint according to claim 1, wherein, the non-right angled edge includes one of an arcuate curve, a rounded edge, a chamfered edge, or a beveled edge.

9. The rotary joint according to claim 1, wherein, the lip is coupled to the non-right angled edge, the external closure member surface, and the side surface.

10. The rotary joint according to claim 1, wherein, the component is a control arm, a tie rod, a ball arm, or a stabilizer bar.

11. A method, the method comprising: providing a housing, the housing comprising: An external mounting surface for coupling to a component; An internal chamber having an internal surface that forms a spherical segment symmetric about a central point; and A lip defining a hole; Positioning a stud within the internal chamber, the stud having: a longitudinal axis passing through the central point, a proximal end having a surface defining the spherical segment, the surface of the proximal end matching the internal surface of the at least one internal housing member, the proximal end being configured to allow the stud to rotate about its longitudinal axis and optionally swing out of angle relative to the central point; Positioning a closure member within the housing to secure the proximal end within the housing, the closure member including a non-right angle edge positioned between an outer surface and a side surface of the closure member; and Positioning the lip adjacent and contiguous to the closure member, the lip extending away from a plane defined by the outer closure member surface; Laminating the lip to the non-right angle edge of the closure member to form a laminate.

12. The method of claim 11, wherein, Laminating the lip includes pressing a die face of a die into the lip, the die face defining a plane positioned at a die angle relative to the longitudinal axis of the housing; and pressing the lip against the non-right angle edge to form the laminate having a length and a thickness.

13. The method of claim 12, wherein, The die is a rotary die and laminating the lip includes: Rotating the die or the housing about the longitudinal axis of the housing at a rotational speed; and Feeding the die towards the lip at a feed rate.

14. The method of claim 12, wherein, The die angle is at least one of: in the range of 45 - 70 degrees, and / or about 61.5 degrees.

15. The method of claim 12, wherein, The rotational speed is at least one of: in the range of 100 - 200 rpm, and / or about 150 rpm.

16. The method of claim 12, wherein, The feed rate is in the range of 0.01 mm / s to 0.5 mm / s, preferably about 0.2 mm / s.

17. The method of claim 11, wherein, The non-right angle edge includes an angled surface having a tangent at a first angle relative to a first plane and at a second angle relative to a second plane, the first plane being defined by a first tangent of the outer closure member surface and the second plane being defined by a second tangent of the side surface.

18. The method of claim 17, wherein, The first angle or the second angle is in the range of 1 - 45 degrees, in the range of 10 - 30 degrees, or about 20 degrees.

19. The method of claim 11, wherein, The non-right angle edge includes one of an arcuate curve, a rounded edge, a chamfered edge, or a beveled edge.

20. A mechanical assembly, the mechanical assembly comprising: A suspension member or a steering member, the suspension member or the steering member being coupled to a swivel joint, the swivel joint comprising: A housing having: An external mounting surface for coupling to a component; At least one internal housing member defining an internal chamber having an internal surface that forms a spherical segment symmetric about a center point; A stud having a longitudinal axis passing through the center point, a proximal end having a surface defining the spherical segment, the surface of the proximal end matching the internal surface of the at least one internal housing member, the proximal end being configured to allow the stud to rotate about its longitudinal axis and optionally swing out of angle relative to the center point; A closure member for securing the proximal end within the housing, the closure member including a non-right angled edge positioned between an external surface and a side surface of the closure member; A lip positioned adjacent to the side surface on the housing, the lip including a laminate coupled to the non-right angled edge for securing the proximal end within the internal chamber.

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