Integrated ball joint

Abstract

Described are ball joints and methods of forming a ball joint. The ball joint comprises a pair of opposed stamped components, a ball stud and an integrated bushing. Each stamped component has a flange. The ball stud is sandwiched between the flanges and has a spherically shaped head with a generally flat top section. The flanges are connected about the spherically shaped head. The integrated bushing is formed by overmolding the spherically shaped head and the flanges. The spherically shaped head is generally encapsulated by the overmolded integrated bushing aside from the generally flat top section thereby providing a greasing access aperture in the integrated bushing.

Description

INTEGRATED BALL JOINTCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority from United States Provisional Patent Application Number 63 / 751,547 filed on January 30, 2025, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates to ball joints, and more particularly to integrated ball joints which may be utilized in suspension systems.BACKGROUND

[0003] Ball joints are typically used in many automotive components, such as vehicle suspension control arms and steering links. In a conventional system, the ball joint assembly is made up of multiple components including at least a steel housing, a steel lid, a ball stud and a plastic bushing. The housing is typically affixed to the control arm by mechanical means (for example, by press-fit and swaging, or welding). The ball stud and bushing are typically captured in the steel housing by the steel cap, which is affixed to the housing. These multiple components typically add cost and weight to the structure. It would be desirable to develop a ball joint which overcomes these problems.SUMMARY

[0004] According to some embodiments there is provided a ball joint. The ball joint comprises a pair of opposed stamped components, a ball stud and an integrated bushing. Each one of the pair of opposed stamped components comprises a flange. The ball stud is sandwiched between the flanges and has a spherically shaped head with a generally flat top section. The flanges are connected about the spherically shaped head. The integrated bushing is formed by overmolding the spherically shaped head and the flanges, wherein the spherically shaped head is generally encapsulated by the overmolded integrated bushing aside from the generally flat top section thereby providing a greasing access aperture in the integrated bushing.

[0005] According to some embodiments, the flanges are swaged onto the spherically shaped head, thereby trapping the spherically shaped head therebetween.

[0006] According to some embodiments, the integrated bushing is formed from injection molded plastic, such as polyoxymethylene.

[0007] According to some embodiments, the ball joint further comprises a cap coupled to the integrated bushing and covering the greasing access aperture. According to some embodiments, the cap is coupled to the integrated bushing using ultrasonic welding. According to some embodiments the ball joint further comprises at least one ridge formed in the integrated bushing proximate the greasing access aperture and configured to facilitate ultrasonic welding.

[0008] According to some embodiments, the ball joint further comprises a boot coupled to an underside of the integrated bushing and to the ball stud, wherein the boot is configured to retain grease therein. According to some embodiments, the boot is formed from rubber (natural or synthetic) or other suitable flexible synthetic material.

[0009] According to some embodiments, the pair of opposed stamped components are formed of High Strength Low Alloy (HSLA) steel.

[0010] According to some embodiments there is provided a method of forming a ball joint. The method comprises: providing a pair of opposed stamped components, each having a flange, wherein at least one of the flanges is an open flange; coupling the pair of opposed stamped components to each other proximate the open flanges, providing an opening therethrough; inserting a spherically shaped head of a ball stud into the opening; shaping the at least one open flange about the spherically shaped head; overmolding the spherically shaped head and the shaped flanges to form an integrated bushing, the overmolded integrated bushing generally encapsulating the spherically shaped head aside from a generally flat top section of the spherically shaped head thereby providing a greasing access aperture in the integrated bushing; injecting grease through the greasing access aperture; and greasing an underside of the spherically shaped head and the integrated bushing.

[0011] According to some embodiments, the shaping comprises swaging the at least one open flange, trapping the spherically shaped head therein.

[0012] According to some embodiments, the method further comprises articulating the ball stud within the integrated bushing to distribute the grease.

[0013] According to some embodiments, the method further comprises installing a boot to the underside of the integrated bushing and to the ball stud.

[0014] According to some embodiments, the method further comprises coupling a cap to the integrated bushing, covering the greasing access aperture.

[0015] According to some embodiments, the method further comprises sealing the grease within one or more interior regions defined by one or more of the boot, the ball stud, the integrated bushing and the cap.

[0016] According to some embodiments, the overmolding is performed using injection molding.

[0017] According to some embodiments, the coupling of the pair of opposed stamped components to each other is performed using welding. According to some embodiments, the welding comprises one or more of laser welding, projection welding and Gas Metal Arc Welding (GM AW).

[0018] Further aspects and embodiments of the claimed subject matter will be apparent from the following description and explanations.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] For a better understanding of the various embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings in which:

[0020] FIG. 1A depicts a front, perspective view of a ball joint, according to nonlimiting embodiments;

[0021] FIG. IB depicts a cross-sectional view of the ball joint of FIG. 1A;

[0022] FIG. 2 depicts an enlarged, cross-sectional view of the ball joint of FIG. 1A;

[0023] FIG. 3A depicts an exploded view of a ball joint, according to non-limiting embodiments;

[0024] FIG. 3B depicts a front, perspective view of the ball joint of FIG. 3 A;

[0025] FIG. 4A depicts the coupling of a pair of opposed stamped components of a ball joint as part of a non-limiting, exemplary method of forming a ball joint;

[0026] FIG. 4B depicts shaping of flanges about a spherically shaped head of a ball stud as part of a non-limiting, exemplary method of forming a ball joint;

[0027] FIGS. 4C and 4D depict overmolding the spherically shaped head of a ball stud and the flanges to form an integrated bushing as part of a non-limiting, exemplary method of forming a ball joint;

[0028] FIG. 4E depicts features of tooling implements involved in the overmolding depicted in FIGS. 4C and 4D as part of a non-limiting, exemplary method of forming a ball joint (ball stud and integrated bushing removed for clarity);

[0029] FIG. 4F depicts an enlarged top view of an integrated bushing of a ball joint, according to non-limiting embodiments;

[0030] FIG. 4G depicts an enlarged bottom view of an integrated bushing of a ball joint, according to non-limiting embodiments;

[0031] FIG. 4H depicts an enlarged, cross-sectional view of grease application in a ball joint, according to non-limiting embodiments;

[0032] FIG. 41 depicts an enlarged, cross-sectional view of a ball joint having a cap, according to non-limiting embodiments;

[0033] FIG. 4J depicts an enlarged, cross-sectional view of a ball joint having a boot (prior to final installation), according to non-limiting embodiments;

[0034] FIG. 4K depicts an enlarged, cross-sectional view of the ball joint of FIG. 4J after the boot has been installed, according to non-limiting embodiments;

[0035] FIG. 5 depicts an enlarged, cross-sectional view of the ball joint of FIG. 4K after grease application, according to non-limiting embodiments; and

[0036] FIG. 6 depicts a flowchart of a method of forming a ball j oint, according to nonlimiting embodiments.

[0037] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Featuresdescribed in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.DETAILED DESCRIPTION

[0038] As noted above, conventional ball joint systems tend to include a separate steel housing and lid, adding undesirable cost and weight to the structure. In contrast, in the described ball joint and method of forming a ball joint the steel housing and steel lid are eliminated, reducing overall cost and weight. Features of the joined components are incorporated into the ball joint structure. For example, flanges formed in a pair of opposed stamped components (e.g., control arm stampings) take the place of the housing and are formed to the final shape with the ball stud in place, helping to ensure a high retention force on the ball stud. The bushing is overmolded directly onto the stamped components, with the ball stud in place during the overmolding. This typically approximates a perfect zero-free play joint. The joint is then greased through an access aperture while the ball stud is articulated for grease distribution. The ball joint is sealed on top with a cap coupled to the overmolded bushing and usually formed of plastic. Any suitable method of coupling the cap to the overmolded bushing is contemplated. For example, according to some embodiments, the cap is coupled to the bushing by ultrasonic welding. A boot may be added below the bushing to complete the sealing of the ball joint. The boot may be formed or otherwise comprise any suitable material, such as rubber (natural or synthetic) or other suitable flexible synthetic material.

[0039] The described ball joint, according to some embodiments, comprises several interesting features such as: the inclusion of an access aperture left after the overmolding for grease injection; the overmolded bushing follows the spherical shape of the ball stud head aside from the generally flat top surface of the ball stud; the grease injection includes the articulation of the ball stud having a generally flat top surface that provides a path for grease ingress; and the sealing of the grease access with a welded cap (e.g., via ultrasonically welding).

[0040] It will be appreciated that numerous specific details are set forth in order to provide a thorough understanding of the exemplary aspects of the present application described herein. However, it will be understood by those of ordinary skill in the art that the exemplaryaspects described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the exemplary aspects described herein. Also, the description is not to be considered as limiting the scope of the exemplary aspects described herein. Any systems, method steps, method blocks, components, parts of components, and the like described herein in the singular are to be interpreted as also including a description of such systems, method steps or tasks, components, parts of components, and the like in the plural, and vice versa. Further aspects of the invention will be apparent from the figures and claims appended hereto. The particular arrangement of the elements described herein may be modified as will be apparent to those skilled in the art.

[0041] Attention is directed to FIGS. 1 A to 2, which depict components of a ball joint 100, according to non-limiting embodiments. According to some embodiments, ball joint 100 comprises a pair of opposed stamped components 102 (individually referred to herein as first opposed stamped component 102A, or upper stamping 102 A, and second opposed stamped component 102B, or lower stamping 102B), a ball stud 104 and an integrated bushing 106. According to some embodiments, the pair of stamped components 102 may be upper and lower stampings of a suspension control arm. The pair of stamped components 102 may be formed of any suitable material or combination of materials, such as High Strength Alloy (HSA) steel. As shown in FIG. 2, each stamped component 102A, 102B comprises a flange, such as flanges 108 (individually, flange 108 A and flange 108B). At least one of flanges 108 will initially be open (sized and shaped to allow the positioning of a spherically shaped head 110 of ball stud 104 to be inserted therebetween).

[0042] Ball stud 104 is sandwiched between the flanges 108. The spherically shaped head 110 of the ball stud 104 (also referred to herein as the “ball” of the ball stud 104) has a generally flat section 112, which may be located on the top of the spherically shaped head 110 (however, it is understood that the location of the “top” section of the spherically shaped head 110 is relative to the ball stud 104 and not necessarily the overall orientation of the ball joint 100) (FIG.2). When complete, the flanges 108 are connected about the spherically shaped head 110 of the ball stud 104. According to some embodiments, the flanges 108 are shaped so as to at least partially encapsulate the spherically shaped head 110, trapping the spherically shaped head 110therebetween. For example, according to some embodiments, the flanges 108 are swaged onto the spherically shaped head 110, thereby trapping the spherically shaped head 110 therebetween. However, any suitable method of shaping the flanges 108 is contemplated.

[0043] The integrated bushing 106 is formed by overmolding the spherically shaped head 110 and flanges 108. Any suitable material or combination of materials is contemplated for the integrated bushing. For example, the integrated bushing 106 may be formed of injection molded plastic, such as polyoxymethylene (e.g., DELRIN® 500P), or any other suitable synthetic material or combinations thereof. The spherically shaped head 110 is generally encapsulated by the overmolded integrated bushing 106 aside from the generally flat top section 112, thereby creating a greasing access aperture 114 in the integrated bushing 106 (see FIG. 2).

[0044] According to some embodiments, the described ball joint 100 further comprises a cap 116 coupled to the integrated bushing 106 and covering the greasing access aperture 114. Any suitable method of coupling the cap 116 to the integrated bushing 106 is contemplated. For example, according to some embodiments, the cap 116 is coupled to the integrated bushing 106 using ultrasonic welding (an example of which is described further below). To facilitate the ultrasonic welding, the integrated bushing 106 may comprise at least one ridge 118 proximate the greasing access aperture 114 (FIG. 4F).

[0045] According to some embodiments, ball joint 100 may further comprise a boot 120 coupled to an underside surface 122 of the integrated bushing 106 and to the ball stud 104 (see, for example, FIGS. 3A, 3B and 4K). Boot 120 is configured to retain grease 124 within an envelope 126 defined by the integrated bushing 106 and the ball stud 104 (FIG. 5). Boot 120 may comprise any suitable material or combination of materials. For example, boot 120 may be formed from rubber (natural or synthetic) or other suitable flexible synthetic material.

[0046] Attention is directed to FIGS. 4A to 4K and FIG. 6, which depict an exemplary, non-limiting method 200 of forming a ball joint. In order to assist in the explanation of method 200, it will be assumed that method 200 is performed using the described ball joint 100 and components thereof. Furthermore, the following discussion of method 200 will lead to a further understanding of ball joint 100 depicted in FIGS. 1A to 3B and the various components as described herein. However, it is understood that method 200 can be varied, and need not workexactly as discussed herein, and that such variations are within the scope of the present application. It is also emphasized, however, that method 200 need not be performed in the exact sequence as shown, unless otherwise indicated; and likewise various blocks may be performed in parallel rather than in sequence. Hence, the elements of method 200 are referred to herein as “blocks” rather than “steps”.

[0047] At block 202, a pair of opposed stamped components 102, in which at least one of the opposed stamped components 102 has an open flange, is provided. For example, as shown in FIG. 4A, the first opposed stamped component 102A initially comprises an open flange 108A (also referred to herein as an upper open flange) and the second opposed stamped component 102B is formed with its final flange shape. However, according to some embodiments, flange 108B comprises an open flange and flange 108A is provided with its final flange shape. According to some embodiments, both flanges 108 A and 108B are initially provided as open flanges to be shaped later in method 200.

[0048] At block 204, the pair of opposed stamped components 102 are coupled to each other proximate the flanges 108 and an opening 128 is formed for the ball stud 104 therethrough. Any suitable method of coupling the pair of opposed stamped components 102 is contemplated. For example, according to some embodiments, the coupling is performed by welding, such as laser welding, projection welding and Gas Metal Arc Welding (GMAW) (producing welding 130 shown in FIG. 4A). The welding 130 about the flanges 108 need not be continuous, as the subsequent overmolding typically creates a sealed joint.

[0049] At block 206, the spherically shaped head 110 of the ball stud 104 is inserted into the opening 128. In particular, the spherically shaped head 110 is positioned in the opening 128 between the flanges 108.

[0050] At block 208, the open flange or flanges (flange 108A and / or flange 108B) is then shaped about the spherically shaped head 110 (FIG. 4B). For example, according to some embodiments, the open flange or flanges is swaged to trap the spherically shaped head 110 therein. As shown in FIG. 4B, the ball stud 104 and stamped components 102 as an assembly may be loaded into a swaging fixture 132. A swaging tool 134 forms the final flange shape in the stamped component having the open flange or flanges (such as upper stamped component 102A havingflange 108 A), trapping the spherically shaped head 110 of the ball stud 104 between the shaped flanges 108. This process typically ensures a high retention force in the final part since the retention of the ball stud 104 is not reliant solely on the integrated bushing 106.

[0051] At block 210, the spherically shaped head 110 of the ball stud 104 and the flanges 108 are then overmolded to form an integrated bushing, such as integrated bushing 106 (FIGS. 4C and 4D). The overmolding results in the general encapsulation of the spherically shaped head 110 aside from the generally flat top section 112, thereby providing a greasing access aperture 114 in the integrated bushing 106. Any suitable method to perform the overmolding is contemplated. For example, according to some embodiments, the overmolding is performed using injection molding.

[0052] In performing the injection molding, the ball stud 104 and stamped components 102 as an assembly may be loaded into the injection molding tool (FIGS. 4C and 4D). The injection molding tool comprises an upper tool 136, a lower tool 138 and an injection tool 140. The lower tool 138 locates the ball stud 104 on the spherically shaped head 110 and the lower stamping flange 108B to help ensure concentricity. One or more of the upper tool 136 and the lower tool 138 may comprise at least one flange locator 142 to assist with locating the respective tool. According to some embodiments, the lower tool 138 comprises the at least one flange locator to assist with locating the lower tool 138 relative to the respective flange and the spherically shaped head 110 of the ball stud 104 (FIG. 4E). According to some embodiments, the lower tool 138 may comprise a ball stud location surface 144 configured to position the spherically shaped head 110 of the ball stud 104 relative to the lower tool 138. The upper and lower tools 136, 138 clamp the pair of opposed stamped components 102 around the flange 108 area to seal off the injection cavity. The injection molding material 141 (e.g., plastic) flows through the injection tool 140 around the flanges 108, generally encapsulating the spherically shaped head 110 with openings only on the top and bottom (leaving the post 146 of the ball stud 104 generally free of the injection molding material). The injection tool 140 is configured to clamp down on the spherically shaped head 110 and prevents the injection molding material 141 from forming over the generally flat top surface 112 (which typically ensures the spherically shaped head 110 can articulate in the integrated bushing 106, as discussed further below). The injection molding material 141 is injected into acavity formed by the upper and lower tools 136, 138, the flanges 108 and ball stud 104, forming the integrated bushing 106. The resulting joint typically approximates zero free play, with all tolerances in the size of the spherically shaped head 110 and the stamping forms at least partially compensated by the injection molding process.

[0053] If a cap 116 is to be included in the ball joint 100 and attached by ultrasonic welding (after greasing), at least one ridge 118 is formed in the integrated bushing 106 proximate the greasing access aperture 114 during the injection molding so as to facilitate the ultrasonic welding (FIGS. 4F, 4G and 41). However, any suitable method of coupling the cap 116 to the integrated bushing 106 to help ensure the top of the ball joint 100 is sealed from water and dirt intrusion and to help trap the grease inside the ball joint 100 is contemplated.

[0054] At block 212, grease 124 is injected through the greasing access aperture 114 (FIG. 4H). According to some embodiments, grease 124 is injected at approximately 2000 psi, although the grease 124 may be injected at any suitable pressure. Any suitable composition of grease 124 is contemplated. According to some embodiments, grease 124 comprises any suitable synthetic grease.

[0055] According to some embodiments, while injecting grease 124 or shortly thereafter, ball stud 104 is articulated within integrated bushing 106 to distribute grease 124 within ball joint 100. For example, according to some embodiments, to help ensure grease 124 is distributed evenly throughout ball joint 100, ball stud 104 is rotated and / or tilted within the integrated bushing 106. Such movement of ball stud 104 typically allows grease 124 to flow through a space formed between the generally flat top section 112 and the integrated bushing 106 during the articulation of ball stud 104 within integrated bushing 106. According to some embodiments, articulating ball stud 104 comprises one or more of tilting ball stud 104 within integrated bushing 106 (such as to about 25 degrees from a ball joint axis, A) and / or rotating ball stud 104 within integrated bushing 106 (such as to about 270 degrees in at least one direction about, for example, ball joint axis, A, or another suitable longitudinal axis formed by ball stud 104)(FIG. 4H). As noted above, the generally flat top section 112 or external surface of the spherically shaped head 110 provides a path for the grease 124 to move into the ball joint 100 as the ball stud 104 is tilted and / or rotated.

[0056] According to some embodiments, at block 214, grease 124 is also applied to at least the underside surface 150 of the spherically shaped head 110 of the ball stud 104 and the underside surface 122 of the integrated bushing 106. According to some embodiments, a boot 120 may also be installed to the underside surface 122 of the integrated bushing 106 and to the ball stud 104 (FIGS. 4J and 4K). The boot 120 may be formed of any suitable material or combination of materials, such as rubber (natural or synthetic) or other suitable flexible synthetic material. Once the boot 120 is installed, typically the grease 124 is sealed within one or more interior regions 127 of the ball joint 100 defined by one or more of the boot 120, the ball stud 104, the integrated bushing 106 and the cap 116 (FIG. 5).

[0057] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the figures, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

[0058] It will also be understood that for the purposes of this application, "at least one of X, Y, and Z" or "one or more of X, Y, and Z" language can be construed as X only, Y only, Z only, or any combination of two or more items X, Y, and Z (e.g., XYZ, XYY, YZ, ZZ, XX, XY).

[0059] In the present application, components may be described as being "configured to" or "enabled to" perform one or more functions. Generally, it is understood that a component that is configured to or enabled to perform a function is configured to or enabled to perform the function, or is suitable for performing the function, or is adapted to perform the function, or is operable to perform the function, or is otherwise capable of performing the function.

[0060] Additionally, components in the present application may be described as being "operatively connected to", "operatively coupled to", and the like, to other components. It is understood that such components are connected or coupled to each other in a manner to perform a certain function. It is also understood that "connections", "coupling" and the like, as recited in the present application include direct and indirect connections between components.

[0061] References in the application to "one embodiment", "an embodiment", "an implementation", "a variant", etc., indicate that the embodiment, implementation or variant described may include a particular aspect, feature, structure, or characteristic, but not everyembodiment, implementation or variant necessarily includes that aspect, feature, structure, or characteristic. Moreover, such phrases may, but do not necessarily, refer to the same embodiment referred to in other portions of the specification. Further, when a particular aspect, feature, structure, or characteristic is described in connection with an embodiment, it is within the knowledge of one skilled in the art to affect or connect such module, aspect, feature, structure, or characteristic with other embodiments, whether or not explicitly described. In other words, any module, element or feature may be combined with any other element or feature in different embodiments, unless there is an obvious or inherent incompatibility, or it is specifically excluded.

[0062] It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for the use of exclusive terminology, such as "solely", "only", and the like, in connection with the recitation of claim elements or use of a "negative" limitation. The terms "preferably", "preferred", "prefer", "optionally", "may", and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.

[0063] The singular forms "a", "an", and "the" include the plural reference unless the context clearly dictates otherwise. The term "and / or" means any one of the items, any combination of the items, or all of the items with which this term is associated. The phrase "one or more" is readily understood by one of skill in the art, particularly when read in context of its usage.

[0064] The term "about" can refer to a variation of± 5%, ± 10%, ± 20%, or ± 25% of the value specified. For example, "about 50" percent can in some embodiments carry a variation from 45 to 55 percent. For integer ranges, the term "about" can include one or two integers greater than and / or less than a recited integer at each end of the range. Unless indicated otherwise herein, the term "about" is intended to include values and ranges proximate to the recited range that are equivalent in terms of the functionality of the composition, or the embodiment.

[0065] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges recited herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. A recited range includes each specific value, integer, decimal, or identity within the range. Any listed range can be easily recognized assufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc.

[0066] As will also be understood by one skilled in the art, all language such as "up to", "at least", "greater than", "less than", "more than", "or more", and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into sub-ranges as discussed above. In the same manner, all ratios recited herein also include all sub-ratios falling within the broader ratio.

[0067] Persons skilled in the art will appreciate that there are yet more alternative implementations and modifications possible, and that the above examples are only illustrations of one or more implementations. The scope, therefore, is only to be limited by the claims appended hereto.

Claims

CLAIMS1. A ball j oint comprising:a pair of opposed stamped components, each stamped component having a flange;a ball stud sandwiched between the flanges, the ball stud having a spherically shaped head with a generally flat top section, wherein the flanges are connected about the spherically shaped head; andan integrated bushing formed by overmolding the spherically shaped head and the flanges, wherein the spherically shaped head is generally encapsulated by the overmolded integrated bushing aside from the generally flat top section thereby providing a greasing access aperture in the integrated bushing.

2. The ball joint of claim 1, wherein the flanges are swaged onto the spherically shaped head, thereby trapping the spherically shaped head therebetween.

3. The ball joint of either claim 1 or claim 2, wherein the integrated bushing is formed from injection molded plastic, preferably polyoxymethylene.

4. The ball joint of any one of claims 1 to 3, further comprising a cap coupled to the integrated bushing and covering the greasing access aperture.

5. The ball joint of claim 4, wherein the cap is coupled to the integrated bushing using ultrasonic welding.

6. The ball joint of claim 5, further comprising at least one ridge formed in the integrated bushing proximate the greasing access aperture and configured to facilitate the ultrasonic welding.

7. The ball joint of any one of claims 1 to 6, further comprising a boot coupled to an underside of the integrated bushing and to the ball stud, wherein the boot is configured to retain grease therein.

8. The ball joint of claim 7, wherein the boot is formed from natural rubber, synthetic rubber, any other suitable flexible synthetic material or any suitable combinations thereof.

9. The ball joint according to any one of claims 1 to 8, wherein the pair of opposed stamped components are formed of High Strength Low Alloy (HSLA) steel.

10. A method of forming a ball joint comprising:providing a pair of opposed stamped components, each having a flange, wherein at least one of the flanges is an open flange;coupling the pair of opposed stamped components to each other proximate the open flanges, providing an opening therethrough;inserting a spherically shaped head of a ball stud into the opening;shaping the at least one open flanges about the spherically shaped head;overmolding the spherically shaped head and the flanges to form an integrated bushing, the overmolded integrated bushing generally encapsulating the spherically shaped head except for a generally flat top section of the spherically shaped head thereby providing a greasing access aperture in the integrated bushing;injecting grease through the greasing access aperture; andgreasing an underside of the spherically shaped head and the integrated bushing.

11. The method of claim 10, wherein the shaping comprises swaging the at least one open flange, trapping the spherically shaped head therein.

12. The method of either claim 10 or claim 11 further comprising articulating the ball stud within the integrated bushing to distribute the grease.

13. The method of any one of claims 10 to 12 further comprising installing a boot to the underside of the integrated bushing and to the ball stud.

14. The method of any one of claims 10 to 13 further comprising coupling a cap to the integrated bushing, covering the greasing access aperture.

15. The method of any one of claims 13 to 14 further comprising sealing the grease within one or more interior regions defined by one or more of the boot, the ball stud, the integrated bushing and the cap.

16. The method of any one of claims 10 to 15, wherein the overmolding is performed using injection molding.

17. The method of claim 16, wherein the overmolding is fabricated from plastic, preferably polyoxymethylene.

18. The method of any one of claims 10 to 17, wherein the coupling of the pair of opposed stamped components to each other is performed using welding.

19. The method of claim 18, wherein the welding comprises one or more of laser welding, projection welding and Gas Metal Arc Welding (GMAW).

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