Vehicle driver and method for its manufacture

Abstract

According to an exemplary embodiment of the present invention, there is provided a vehicle control arm, comprising: a ball stud (260) having a ball member (262) and a rod member (264) configured to extend from one side of the ball member (262); a control arm (100) having a ball stud seat portion (220) formed integrally with the control arm (100), the ball stud seat portion (220) having a ball stud seat surface (223) partially in contact with a lower portion of the ball member (262); and an insert molding (240) configured to be connected to the ball stud seat portion (220) and configured to enclose an outer peripheral surface of the ball member (262). The insert molded part (240) is configured to be injection molded by insert molding in a state in which the ball element (262) is seated as an insert on the ball stud seat part (220).

Description

Vehicle driver and method for its manufactureTechnical field

[0001] The present invention relates to a vehicle control arm and a method for manufacturing the same, and more particularly to a vehicle control arm having a ball joint provided at least at one end of the control arm and a method for manufacturing the same. background

[0002] Generally, a suspension used in a vehicle is provided between a vehicle body and a wheel to connect the vehicle body and the wheel as rigid bodies through one or more links. The suspension is supported by a spring, a hydraulic shock absorber, and the like in a vertical direction. The suspension has a function of appropriately compensating for relative mechanical movement between the vehicle body and the wheel through a suitable combination of high rigidity and flexibility in other directions.

[0003] In recent years, a multi-link suspension has been developed and applied to a production vehicle, which is capable of efficiently absorbing shocks and vibrations emanating from a road surface as well as vibrations of the vehicle body through an ideal kinematic movement using at least three or more links.

[0004] A vehicle control arm used in a prior art multi-link suspension includes a control arm with a ball joint (serving as a spheroidal joint). The ball joint may include a ball stud and a socket configured to enclose the ball stud. The socket may be integrally injection-molded with the control arm. Lubricating oil may be injected into the interior of the socket to frictionlessly operate a ball element of the ball joint.

[0005] Generally, the ball element of the ball stud in the prior art has a flat section. Fig. 1A to 1G show an example of a method for manufacturing the ball stud in the prior art. As shown in the Fig. 1A to 1G, the ball stud is produced by cutting a cylindrical, rod-shaped metallic material to a specific size (cf. Fig. 1A), performing a preforming process (cf. Fig. 1B), forming a section that becomes one side of a bar element (cf. Fig. 1 C), preforming a section corresponding to a spherical element (cf. Fig. 1D), forming the spherical section in a finer shape (cf. Fig. 1E), forming a neck-like portion between the ball element and the rod element and performing a final forming process to obtain a final shape (cf. Fig. 1F). In the above-described method for forming the ball stud, the spherical portion of the ball member is formed in a state where the rod member is disposed on one side of the ball stud. This makes it difficult to accurately mold the spherical portion. Generally, a flat portion may be formed in the ball stud. Due to the presence of the flat portion, it may be difficult to injection-mold a socket in a state where the ball stud is inserted. When the socket is injection-molded in the state where the ball stud is inserted, the injection-molded socket may come into contact with the flat portion of the ball stud due to the flat portion. This prevents the ball stud from rotating in the socket.

[0006] Furthermore, in the case of a welded ball stud in which the ball member and the rod member are joined by welding, the ball member is formed in a state where there is no rod member on one side of the ball member. Therefore, the ball member can have a completely spherical shape. However, in a case where the socket with the welded ball stud inserted is injection molded, it is difficult to introduce lubricant into the interior of the socket after the socket is injection molded. In addition, to introduce the lubricant into the socket, an opening must be formed in the socket. This allows the lubricant to leak out of the socket through the opening.

[0007] Furthermore, in a process where the lubricant is injected into the cup after injection molding and the ball stud is press-fitted into the cup, there is a limit to the design diameter of a hole through which the ball stud is press-fitted into the cup. This may limit the pull-out resistance of the ball stud. Prior art documentPatent document

[0008] Patent Document 1: Korean Patent Application No. 10-2022-0078384 (June 10, 2022) Brief description of the invention

[0009] The present invention has been developed to solve the above-mentioned problems, and the present invention has a purpose of providing a vehicle control arm in which a ball joint can be injection-molded in a state where the ball stud is inserted even if the ball stud has a flat portion, and a method of manufacturing the vehicle control arm.

[0010] Furthermore, the present invention serves the purpose of providing a vehicle control arm in which a lubricant can be likely introduced into a socket but is unlikely to leak from the socket, and there are no restrictions on the design of a pull-out resistance of a ball stud, and a method for manufacturing the vehicle control arm. In the present specification, the pull-out resistance refers to the ability of a ball element of the ball stud to withstand a certain force without being pulled out of an insert molding.

[0011] According to an exemplary embodiment of the present invention, a vehicle control arm may include: a ball stud 260 having a ball member 262 and a rod member 264 formed to extend from one side of the ball member 262; a control arm 100 having a ball stud seat portion 220 formed integrally with the control arm 100, the ball stud seat portion 220 having a ball stud seat surface 223 partially in contact with a lower portion of the ball member 262; and an insert molded portion 240 configured to be joined to the ball stud seat portion 220 and configured to enclose an outer peripheral surface of the ball member 262. The insert molded portion 240 may be configured to be injection-molded by insert molding in a state where the ball member 262 is insert-fitted onto the ball stud seat portion 220.

[0012] According to one aspect, the ball member 262 may have a flat portion 261 provided at a lower portion of the ball member 262, and the insert molded part 240 may be injection molded in a state where an outer surface different from the flat portion 261 of the ball member 262 is seated on the ball stud seat surface 223, and the insert molded part 240 may not be in contact with the flat portion 261 of the ball member 262.

[0013] In one aspect, the insert molding 240 may include a first insert molding 242 disposed on an upper surface of the ball stud seat portion 220, a second insert molding 244 disposed on a lower surface of the ball stud seat portion 220, and a third insert molding 246 configured to connect the first insert molding 242 and the second insert molding 244.

[0014] In one aspect, the ball stud seat part 220 may have one or more through holes 226 formed to extend in a vertical direction, and the third insert molding part 246 may be disposed within the one or more through holes 226.

[0015] According to one aspect, the ball stud seat part 220 may be configured to contact the outer peripheral surface of a lower hemisphere of the ball member 262 located below a virtual horizontal plane P separating an upper hemisphere and the lower hemisphere of the ball member 262.

[0016] In one aspect, the ball stud seat part 220 may be formed in the shape of a plate having a smaller thickness than the handlebar arm 100.

[0017] In one aspect, the one or more through holes 226 may be formed to be spaced apart from one another along a circumferential direction around the ball stud seat surface 223.

[0018] In one aspect, the insert molding 240 may be configured to extend downwardly from a virtual horizontal plane P separating an upper hemisphere and a lower hemisphere of the spherical member, and configured to enclose the outer peripheral surface of the upper hemisphere and at least a portion of the lower hemisphere of the spherical member 262.

[0019] According to another exemplary embodiment of the present invention, a method for manufacturing a vehicle control arm may include the steps of: preparing a ball stud 260 having a ball member 262 and a rod member 264, a mold core 400 for defining a ball stud seating surface, a second mold core 700 for defining an insert molded part, and a core pin 600; arranging the mold core 400 and the core pin 600 in a first injection mold 300; performing a primary injection molding process with respect to the control arm 100 including the ball stud seating part 220 to form a primary injection molded object; applying a lubricant to the ball stud seating part 220 of the primary injection molded object; Connecting the ball stud 260 to the mold core 700 and arranging the ball stud 260 and the mold core 700, which are connected to each other, within a second injection mold 800;and injecting an insert resin into the second injection mold 80 and performing a secondary injection molding process with respect to the insert molded part 240. When arranging the ball stud 260 within the second injection mold 800, a lower portion of the ball element 262 of the ball stud 260 can be brought into contact with the ball stud seat part 220.;

[0020] According to one aspect, the first injection mold 300 may include a molding cavity 320 for molding the ball stud seat part 220, and the molding cavity 320 may include: a first cavity 322 in which the mold core 400 is disposed to define a ball stud seat surface 223 of the ball stud seat part 220; a second cavity 324 for defining an upper surface, a side surface, and a lower surface of the ball stud seat part 220, excluding the ball stud seat surface 223; and a through hole 330 formed to extend from a lower surface of the first injection mold 300 to the second cavity 324.

[0021] In one aspect, the second injection mold 800 may include an insert mold cavity 820 for molding the insert mold 240, and the insert mold cavity 820 may include a third cavity 822 through which the ball stud 260 is inserted and disposed in the second injection mold 800, and a fourth cavity 824 for defining an outer surface of the insert mold disposed on an upper surface and a lower surface of the ball stud seat portion 220.

[0022] In one aspect, the third space 822 may be filled with the second core 700 and a lower portion of the second core 700 defines at least a portion of an upper portion of the insert molding 240.

[0023] According to an exemplary embodiment of the present invention, during an insert molding process, no insert molding is formed in a space between a flat portion of a ball member and a ball stud seat portion. Therefore, the insert molding is not brought into contact with the flat portion of the ball member. Accordingly, even if the ball stud has the flat portion, a ball joint can be easily injection molded in a state where the ball stud is inserted.

[0024] Furthermore, according to an exemplary embodiment of the present invention, after applying lubricant to a ball joint seat part, the insert molded part is injection molded to obtain the ball joint. This eliminates the need to additionally provide a hole for lubricant injection, thereby preventing lubricant leakage and eliminating design constraints regarding the ball stud's pull-out resistance. Short description of the drawings The Fig. 1A to 1G show, by way of example, a method for producing a ball stud according to the prior art; Fig. 2 shows a perspective view of a vehicle handlebar according to an exemplary embodiment of the present invention; Fig. 3 shows an exploded perspective view of the vehicle handlebar according to an exemplary embodiment of the present invention; Fig. 4 is a cross-sectional view showing structures of a ball stud, an insert molding, and a ball stud seat portion according to an exemplary embodiment of the present invention; Fig. 5 shows a perspective view of the vehicle handlebar before the insert molding is formed according to an exemplary embodiment of the present invention; Fig. 6 shows a perspective view of the insert molding according to an exemplary embodiment of the present invention; Fig. 7 shows a flowchart for explaining a method for manufacturing a handlebar arm according to an exemplary embodiment of the present invention; Fig. Fig. 8 is a view showing a primary injection molding process in Fig. 7; Fig. 9 is a view showing a secondary injection molding process in Fig. 7; Fig. 10 shows a first injection mold; and Fig. 11 shows a second injection mold. Detailed description

[0025] Hereinafter, preferred exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0026] In order to clearly describe the present invention, detailed descriptions of parts irrelevant to the present invention are omitted, and the same reference numerals are used for the same components throughout the description. Furthermore, the shape and size of each component illustrated in the drawings are arbitrarily illustrated for convenience of description, so the present invention is not necessarily limited to the illustrated shape and size. That is, it is to be understood that, within the scope of the present invention, certain shapes, structures, and features described herein may be changed from one exemplary embodiment to another exemplary embodiment. Positions or arrangements of individual components or elements may also be changed within the scope of the present invention.Therefore, the detailed description given below is not to be taken in a limiting sense, and the scope of the present invention is to be understood as including the scope claimed in the appended claims and their equivalents.

[0027] Unless the phrase or sentence clearly indicates otherwise, the terms "comprising," "including," "having," and the like as used herein should be construed as open-ended terms that encompass the possibility of including other exemplary embodiments.

[0028] The singular form described herein may include the plural form unless the context clearly indicates otherwise, and this applies equally to the singular form set forth in the claims.

[0029] Terms such as “first,” “second,” and the like are used to distinguish a plurality of components, without limiting the order or importance of the corresponding components.

[0030] Directional terms such as "upward," "up," and the like used in describing a vehicle control arm of the present invention refer to a direction in which a ball stud protrudes among the directions in which a hole of a ball stud seat portion extends in the drawings, and directional terms such as "downward," "below," and the like refer to a direction opposite to this direction. The ball stud seat portion illustrated in the accompanying drawings may be arranged in other directions. Such other directions may be interpreted depending on the situation.

[0031] The present invention relates to a vehicle control arm. Generally, the vehicle control arm is configured to include a control arm and joints arranged at both ends of the control arm. Representative examples of the joints may include a ball joint and a bushing.

[0032] Generally, a multi-link, as an example of a vehicle control arm, is configured to include a ball joint located at one end of the control arm and a bushing located at the other end of the control arm. As another example of the vehicle control arm, a stabilizer link may be configured to include (1) a ball joint located at one end of the control arm and a bushing located at the other end of the control arm, (2) ball joints located at both ends of the control arm, or (3) bushings located at both ends of the control arm.

[0033] The present invention relates to a vehicle control arm in which, even when a ball stud has a flat portion, a ball joint (more precisely, a member surrounding the ball stud) can be injection-molded in a state where the ball stud is inserted. The present invention is not limited to the multi-link or the stabilizer link, but is applicable to any control arm insofar as it has the ball joint.

[0034] The following description mainly focuses on a control arm for a vehicle having a ball joint at one end and a bushing at the other end, but the present invention is not limited thereto. The present invention is also applicable to a vehicle control arm having ball joints at both ends.

[0035] Fig. 2 shows a perspective view of a vehicle driver according to an exemplary embodiment of the present invention. Fig. 3 shows an exploded perspective view of the vehicle handlebar according to an exemplary embodiment of the present invention. Fig. 4 is a cross-sectional view showing structures of a ball stud, an insert molding, and a ball stud seat portion according to an exemplary embodiment of the present invention.

[0036] As in Fig. 2, a vehicle handlebar 1 according to an exemplary embodiment of the present invention comprises a handlebar arm 100 and a ball joint 200 arranged at one end of the handlebar arm 100. In Fig. In Figure 2, the ball joint 200 is shown disposed at one end of the handlebar arm 100, but the configuration is not limited thereto. Alternatively, ball joints may be disposed at both ends of the handlebar arm 100.

[0037] The ball joint 200 according to an exemplary embodiment of the present invention includes a ball stud seat part 220, an insert molded part 240 and a ball stud 260.

[0038] The ball stud 260 is configured to include a ball member 262 and a rod member 264 configured to extend from one side of the ball member 262. The ball member 262 and the rod member 264 are integrally formed with each other.

[0039] The ball member 262 may be enclosed by the insert molding 240 and the ball stud seat member 220, as described later. The ball member 262 may function to move a member connected to the rod member 264 in various directions relative to the insert molding 240.

[0040] In the vehicle control arm of the present invention, even if the ball stud 260 has a flat portion 261, the ball joint 200 can be injection-molded in a state where the ball stud 260 is inserted. The present invention is more preferably applicable to a general ball stud having such a flat portion. The present invention is also applicable to a welded ball joint. The present invention should be understood as not being limited to the ball joint having the flat portion.

[0041] According to an exemplary embodiment of the present invention, the ball seat part 220 may be formed in a plate shape having a flat upper surface 222 as a whole and a lower surface 224. For example, the ball seat part 220 may be injection-molded to be integrally formed with the control arm 100 and may be a plate whose thickness is less than that of the control arm 100.

[0042] A concave ball stud seating surface 223 is formed in the flat upper surface 222 of the ball stud seating part 220 to have a shape that matches a lower shape of the ball member 262. Further, a lubricant receiving groove 225 is formed in the center of the ball stud seating surface 223, in which a lubricant is received. The flat portion 261 of the ball member 262 is spaced from the ball stud seating surface 223 so that the insert molding 240 does not come into contact with the flat portion 261 of the ball member 262, as described below.

[0043] Specifically, the ball stud seating surface 223 is formed such that an outer surface of the ball member 262, excluding the flat portion 261, sits on the ball stud seating surface 223 and comes into contact with the ball stud seating surface 223. For example, the ball stud seating surface 223 may be formed to contact only a lower outer surface of the ball member 262 defined below a virtual horizontal plane P separating the upper and lower hemispheres of the ball member 262. This is because, in a case where the ball stud seating surface 223 is formed to partially come into contact with the upper hemisphere of the ball member 262, the ball stud seating surface 223 is hardly injection-molded in a handlebar manufacturing method described below.

[0044] With the above-described configuration, when the ball member 262 of the ball stud 260 is seated on the ball stud seat surface 223, a space between the flat portion 261 of the ball member 262 and the ball stud seat part 220 (i.e., a space in which the lubricant receiving groove 225 is formed) is separated from a space above the upper surface of the ball stud seat part 220, so that they do not communicate with each other. Therefore, as described later, in a secondary injection molding process, the insert molded part 240 is not formed in the space between the flat portion 261 of the ball member 262 and the ball stud seat part 220 and does not come into contact with the flat portion 261 of the ball member 262.

[0045] The ball stud seat part 220 may have one or more through holes 226 formed to extend in a vertical direction. For example, the through holes 226 may be spaced apart from each other along a circumferential direction of the ball stud seat surface 223.

[0046] Further, according to an exemplary embodiment of the present invention, the insert molding 240 is a part that forms a body of the ball joint 200 (together with the ball stud seat portion 220) and may be configured to have an internal receiving space. The ball element 262 of the ball stud 260 is inserted into and received in the internal receiving space.

[0047] The insert molding 240 may be configured to include a first insert molding 242 disposed on the upper surface 222 of the ball stud seat portion 220, a second insert molding 244 disposed on the lower surface 224 of the ball stud seat portion 220, and a third insert molding 246 connecting the first insert molding 242 and the second insert molding 244.

[0048] The first insert molding 242, together with the ball stud seat part 220, forms a body of the ball joint and provides the receiving space in which the ball element 262 is received. The first insert molding 242 has an inner surface that encloses the ball element 262 together with the ball stud seat part 220 and is brought into sliding contact with the ball element 262. The inner surface has an overall curved surface corresponding to the shape of the ball element 262. The inner surface and the ball stud seat surface 223 of the ball stud seat part 220 have an overall spherical shape.

[0049] The second insert molding 244 is disposed on the lower surface 224 of the ball stud seat part 220. The second insert molding 244 is connected to the first insert molding 242 (which is disposed on the upper surface 222 of the ball stud seat part 220) via the third insert molding 246. During injection molding of the insert molding 240, an insert resin is brought into contact with the ball stud seat part 220. At this time, welding is performed on the surface of the ball stud seat part 220, so that the insert molding 240 and the ball stud seat part 220 are connected to each other. Furthermore, with the above configuration, the insert molding 240 is structurally connected to the ball stud seat part 220, whereby the strength of the ball joint 200 can be improved.

[0050] According to an exemplary embodiment of the present invention, the first insert molding 242 may have a top opening. The rod member 264 of the ball stud 260 may extend out of the first insert molding 242 through the top opening.

[0051] Fig. 5 shows a perspective view of the vehicle handlebar prior to forming the insert molding according to an exemplary embodiment of the present invention. Fig. 6 shows a perspective view of the insert molding according to an exemplary embodiment of the present invention. Fig. 7 shows a flowchart for explaining a method for manufacturing a handlebar arm according to an exemplary embodiment of the present invention. Fig. Fig. 8 is a view showing a primary injection molding process in Fig. 7. Fig. 9 is a view showing a secondary injection molding process in Fig. 7. Fig. 10 shows a first injection mold. Fig. 11 shows a second injection mold.

[0052] Next, a method of manufacturing the vehicle handlebar according to an exemplary embodiment of the present invention will be described with reference to Fig. 5 to 11.

[0053] Although a plurality of steps of the method for manufacturing the vehicle handlebar according to an exemplary embodiment of the present invention described below are described in a specific sequence, these steps do not necessarily have to be performed in the sequence described below. For example, the sequence of some steps may be changed, some of the steps may be omitted, additional steps may be added, or some of the steps may be performed simultaneously.

[0054] As in Fig. 7, the method for manufacturing the vehicle control arm according to an exemplary embodiment of the present invention may include: a step S10 of preparing a ball stud having a ball member and a rod member; a step S20 of arranging a mold core for defining the ball stud seat surface and a core pin in a first injection mold; a step S30 of performing a primary injection molding process with respect to a control arm having the ball stud seat part as a primary molded object; a step S40 of applying a lubricant to the ball stud seat part of the primary molded object; a step S50 of connecting the ball stud to the mold core for defining the insert molded portion and arranging it within a second injection mold; and a step S60 of injecting an insert resin into the second injection mold to perform a secondary injection molding process.

[0055] In particular, according to an exemplary embodiment of the present invention, the process for preparing the ball stud having the ball member and the rod member can be carried out as in a conventional ball stud manufacturing method. For example, the process for preparing the ball stud can be carried out as in the ball stud manufacturing method described with reference to Fig. 1 is shown.

[0056] According to an exemplary embodiment of the present invention, for example, in step S20 for arranging the mold core for defining the ball stud seating surface within the first injection mold, for example, a first injection mold 300 and a mold core 400 for defining the ball stud seating surface, as in Fig. 8 shown.

[0057] As in Fig. 8, the first injection mold 300 has a first right injection mold (in Fig. 8) for defining the right side of the handlebar and a first left injection mold (not shown) for defining the left side of the handlebar. The first right injection mold and the first left injection mold can be connected to each other by a connecting element (not shown).

[0058] The first right injection mold and the first left injection mold are similar in structure. Therefore, the first injection mold 300 will be described primarily with emphasis on the first right injection mold.

[0059] As in Fig. 10, the first injection mold 300 has a ball stud seat part molding space 320 for molding the ball stud seat part 220, a control arm molding space 340 for molding the control arm 100, and a bushing molding space 360 for molding the bushing 120.

[0060] The ball stud seat part mold cavity 320 may include a first cavity 322 into which the mold core 400 is inserted to define the ball stud seat surface 223 of the ball stud seat part 220, and a second cavity 324 for defining upper, side, and lower surfaces of the ball stud seat part 220 excluding the ball stud seat surface 223. A through hole 330 is formed in a lower portion of the first injection mold 300 to extend from the lower surface of the first injection mold 300 to the second cavity 324.

[0061] As in Fig. 8, the mold core 400 may include a ball stud seating surface forming portion 420 having a shape corresponding to that of the ball stud seating surface 223, and a cylindrical extension portion 440 formed to extend upward from the ball stud seating surface forming portion 420.

[0062] The first space 322 of the first injection mold 300 is formed in a shape corresponding to the cylindrical extension portion 440 of the mold core 400. An upper portion of the first space 322 is open, so that the mold core 400 is inserted into the first injection mold 300 through the respective opening.

[0063] The mold core 500 may include a bushing inner peripheral surface shaping portion 520 having a shape corresponding to an inner peripheral surface of the bushing 120, and a cylindrical extension portion 540 formed to extend from one end of the bushing inner peripheral surface shaping portion 520.

[0064] The diameter of the shaping portion 520 for the bushing inner peripheral surface of the mold core 500 may differ from the diameter of the cylindrical extension portion 540 with respect to the shape of the bushing inner peripheral surface. Therefore, to facilitate removal of the mold core 500, the mold core 500 may consist of two parts, for example, an upper mold core and a lower mold core.

[0065] The sleeve molding space 360 may include a fifth space 362 for defining an outer peripheral surface of the sleeve 120 and a sixth space 364 (for defining a cylindrical outer peripheral surface of the sleeve 120) into which the mold core 500 is inserted. The fifth space 362 may be formed in a shape corresponding to the sleeve outer peripheral surface 120, and the sixth space 364 may be formed in a shape (for example, a cylindrical shape) corresponding to the cylindrical extension portion 540 of the mold core 500. The upper and lower portions of the sixth space 364 are open, so that the mold core 500 is disposed inside the first injection mold 300 via the respective openings.

[0066] The mold core 400 and the mold core 500 are arranged inside the first injection mold 300 in the state where the first left injection mold and the first right injection mold are connected to each other by the connecting member. A locking portion (not shown) is formed in an upper end of the cylindrical portion of the mold core 400. Therefore, when the mold core 400 is inserted into the opening of the first injection mold 300, the mold core 400 can be spaced from the lower surface of the second space 324 to form a space for injection molding the ball stud seat part 220.

[0067] Further, the core pin 600 is inserted into and disposed within the through hole 330. The core pin 600 is inserted until it comes into contact with the upper surface of the second space 324.

[0068] As in Fig.8, after arranging the mold core 400, the mold core 500, and the core pin 600 in the first injection mold 300, a resin is injected into the first injection mold 300 to injection mold a primary molded object including the ball stud seat part 220 and the control arm 100.

[0069] Lubricant is then applied to the ball stud seat part 220 of the primary injection molded object.

[0070] Subsequently, the ball stud 260 is inserted into the mold core 700. The primary injection-molded object and the mold core 700, into which the ball stud 260 is inserted, are then arranged in the second injection mold 800.

[0071] Similar to the first injection mold 300, the second injection mold 800 may include a second left injection mold and a second right injection mold. The second right injection mold and the second left injection mold are similar in structure. Therefore, the second injection mold 800 will be described primarily with emphasis on the second right injection mold.

[0072] As an example, the second injection mold 800 has an insert mold cavity 820, a control arm cavity 840, and a bushing cavity 860.

[0073] The control arm space 840 and the bushing space 860 are spaces in which the control arm and the bushing of the primary injection molded object are arranged.

[0074] The insert mold cavity 820 may include a third cavity 822 through which the ball stud 260 is inserted into and disposed within the second injection mold 800, and a fourth cavity 824 for defining the outer surfaces of the first insert mold 242 and the third insert mold 246. The third cavity 822 may be formed as a cylindrical portion having a diameter equal to or slightly larger than the diameter of the ball member 262, such that the ball stud 260 extends through the third cavity 822.

[0075] The third space 822 and the fourth space 824 must have a structure that can functionally communicate with each other. Therefore, the insert resin can penetrate into the third space 822 when the insert resin is injected into the fourth space 824 to form the insert molded part 240.

[0076] To avoid such a situation, the ball stud 260 is disposed within the second injection mold 800 while being inserted into the mold core 700. The third space 822 is filled with the mold core 700. A lower portion of the mold core 700 defines at least a portion of the upper portion of the insert molded part 240.

[0077] The locking portion is formed at the upper end of the mold core 700. Therefore, when the mold core 700 is inserted into the opening of the second injection mold 800, the mold core 700 can be spaced from the lower surface of the fourth space 824 to form the space for injection molding the insert molded part 240.

[0078] After the primary molded object and the mold core 700 are arranged in the second injection mold 800, the insert resin is injected into the second injection mold 800 to injection-mold a secondary molded object including the insert molded part 240. In this configuration, the insert resin is filled into the fourth space 824 and the through hole 226 of the ball stud seat part 220, so that the insert molded part 240 is formed.

[0079] Although preferred exemplary embodiments of the present invention have been described, the present invention is not limited to the exemplary embodiments described above, but within the technical scope of the present invention, other exemplary embodiments may be provided, including all changes that can be easily varied and recognized as equivalent by those skilled in the art to which the present invention belongs. Explanation of reference symbols 1 driver 100 handlebar arm 120 socket 200 ball joint 220 ball stud seat part 222 Upper surface 223 ball stud seat 224 Lower surface 225 Lubricant receiving groove 240 insert casting 330 through hole 242 First insert casting 244 Second insert casting 246 Third insert casting 260 ball studs 261 Flat section 262 spherical element 300 First injection mold 322 First Room 340 handlebar arm molding space 362 Fifth Room 264 rod element 320 ball stud seat part mold space 324 Second Room 360 bushing mold space 364 Sixth Room 400 mold core for defining the ball stud seat surface 420 Forming section for ball stud seats 440, 540 Cylindrical extension section 500 mold core for defining the socket 520 Forming section for bushing inner peripheral surface 600 core pin 700 mold core for defining the insert casting 800 Second injection mold 820 Insert casting mold chamber 840 handlebar arm space 822 Third Room 824 Fourth Room QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] KR 10-2022-0078384

[0008]

Claims

[1] Driver, with: a ball stud (260) having a ball member (262) and a rod member (264) configured to extend from one side of the ball member (262); a control arm (100) having a ball stud seat portion (220) formed integrally with the control arm (100), the ball stud seat portion (220) having a ball stud seat surface (223) partially in contact with a lower portion of the ball member (262); and an insert molded part (240) configured to be connected to the ball stud seat part (220) and configured to enclose an outer peripheral surface of the ball element (262), wherein the insert molded part (240) is configured to be injection molded by insert molding in a state in which the ball element (262) is seated as an insert on the ball stud seat part (220). [2] The vehicle control arm according to claim 1, wherein the ball member (262) has a flat portion (261) provided at a lower portion of the ball member (262), and wherein the insert molded part (240) is injection molded in a state in which an outer surface different from the flat portion (261) of the ball member (262) sits on the ball stud seat surface (223) and the insert molded part (240) is not in contact with the flat portion (261) of the ball member (262). [3] The vehicle control arm of claim 1, wherein the insert molding (240) includes a first insert molding (242) disposed on an upper surface of the ball stud seat part (220), a second insert molding (244) disposed on a lower surface of the ball stud seat part (220), and a third insert molding (246) configured to connect the first insert molding (242) and the second insert molding (244). [4] The vehicle control arm of claim 3, wherein the ball stud seat member (220) has one or more through holes (226) formed to extend in a vertical direction, and wherein the third insert molding (246) is disposed within the one or more through holes (226). [5] The vehicle handlebar according to claim 1, wherein the ball stud seat part (220) is formed to come into contact with the outer peripheral surface of a lower hemisphere of the ball member (262) which is located below a virtual horizontal plane (P) separating an upper hemisphere and the lower hemisphere of the ball member (262). [6] Vehicle handlebar according to claim 1, wherein the ball stud seat part (220) is formed in the form of a plate having a smaller thickness than the handlebar arm (100). [7] A vehicle handlebar according to claim 4, wherein the one or more through holes (226) are formed such that they are arranged spaced apart from one another along a circumferential direction around the ball stud seat surface (223). [8] The vehicle handlebar according to claim 1, wherein the insert molding (240) is configured to extend downward from a virtual horizontal plane (P) separating an upper hemisphere and a lower hemisphere of the ball member, and is configured to enclose the outer peripheral surface of the upper hemisphere and at least a portion of the lower hemisphere of the ball member (262). [9] A method for manufacturing a vehicle steering wheel, the method comprising the steps of: Preparing a ball stud (260) having a ball element (262) and a rod element (264), a mold core (400) for defining a ball stud seating surface, a mold core (700) for defining an insert molding, and a core pin (600); Arranging the mold core (400) and the core pin (600) in a first injection mold (300); performing a primary injection molding process with respect to the control arm (100) having the ball stud seat part (220) to form a primary injection molded object; Applying a lubricant to the ball stud seat part (220) of the primary injection molded object; Connecting the ball stud (260) to the mold core (700) and arranging the ball stud (260) and the mold core (700), which are connected to each other, in a second injection mold (800); and Injecting an insert resin into the second injection mold (800) and performing a secondary injection molding process with respect to the insert molded part (240), wherein, when arranging the ball stud (260) in the second injection mold (800), a lower portion of the ball element (262) of the ball stud (260) is brought into contact with the ball stud seat part (220). [10] The method of claim 9, wherein the first injection mold (300) has a molding cavity (320) for molding the ball stud seat part (220), and wherein the molding cavity (320) comprises: a first space (322) in which the mold core (400) is arranged to define a ball stud seat surface (223) of the ball stud seat part (220); a second space (324) for defining an upper surface, a side surface and a lower surface of the ball stud seat part (220), excluding the ball stud seat surface (223); and a through hole (330) formed to extend from a lower surface of the first injection mold (300) to the second space (324). [11] The method of claim 9, wherein the second injection mold (800) has an insert mold cavity (820) for molding the insert mold (240), and wherein the insert mold cavity (820) has a third cavity (822) through which the ball stud (260) is inserted into and disposed in the second injection mold (800), and a fourth cavity (824) for defining an outer surface of the insert mold disposed on an upper surface and a lower surface of the ball stud seat portion (220). [12] The method of claim 11, wherein the third space (822) is filled with the mold core (700) and a lower portion of the mold core (700) defines at least a portion of an upper portion of the insert molding (240).

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