Cage-Like Ball Joint Insert for Higher Extraction Force
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Solution Overview
Problem
Existing ball joint inserts in motor vehicles face challenges in positioning and handling during over-molding, and the extraction force required to remove the joint ball from the socket or housing is insufficient, particularly in plastic components, limiting the freedom of movement and increasing the risk of premature joint ball removal.
Innovation Solution
A cage-like insert design with a cap element for partial sliding contact and a reinforcing element, allowing for improved positioning and handling during over-molding, and enhancing the extraction force by forming a slide bearing and surrounding the joint ball with a material that is more rigid than the over-molded plastic, thereby reducing the risk of premature joint ball removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cap element is used to cover the pole surface and seal the free space, then the joint ball can rotate and tilt freely, but the positioning and handling during over-molding becomes elaborate and complex
Solution Approach 1:
The insert is divided into two functional parts: a cap element for sealing the free space and an open part-structure for positioning and handling. This segmentation allows each part to optimize its specific function while reducing overall complexity during the over-molding process.
Solution Approach 2:
The open part-structure acts as an intermediary between the cap element and the joint ball, providing a cage-like configuration that facilitates positioning and handling during over-molding while allowing the cap element to maintain its sealing function.
2Ease of manufacture
If plastic components are used for joint socket and housing, then manufacturing is simplified, but the extraction force for removing the joint ball becomes insufficient
Solution Approach 1:
The insert combines a plastic cap element with a metal open part-structure, creating a hybrid component that leverages the manufacturing advantages of plastic while gaining the high strength and rigidity of metal to provide sufficient extraction force.
Solution Approach 2:
Different parts of the insert have different material properties: the cap element is made of plastic for ease of manufacture and sealing, while the open part-structure is made of metal to provide the necessary extraction force and rigidity in critical areas.
3Adaptability or versatility
If the joint socket geometry is optimized for mobility, then tilting movement is enabled, but the extraction force capability is reduced below the required threshold
Solution Approach 1:
The insert separates the functions of enabling mobility (cap element) and providing extraction force (open part-structure), allowing the joint socket geometry to be optimized for mobility without compromising extraction force capability.
Solution Approach 2:
The hybrid plastic-metal construction of the insert allows the plastic portion to accommodate the joint ball with proper mobility while the metal portion provides the necessary extraction force that plastic alone cannot deliver.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cage-like insert design facilitates easier positioning and handling during over-molding and significantly increases the extraction force, ensuring the joint ball can be removed without exceeding a predetermined threshold, thus enhancing the durability and reliability of the ball joint.
Implementation Method 1
having a first part-structure for at least partial sliding contact with a joint ball
Implementation Method 2
the first part-structure can be connected by over-molding to a joint socket and/or a joint housing
Data Source
AI summary
An insert for a ball joint (19) in a motor vehicle. The insert having a first part-structure (6) for making at least partial slide-bearing contact with a joint ball (2). The first part-structure (6) can be connected, by over-molding, to a joint socket (17) and/or to a joint housing (18). The insert (1) can be positioned and/or handled to cover a pole surface, to increase the extraction force, the insert (1) has an open part-structure (20) such that a cage-like configuration can be produced for surrounding the joint ball (2).