Ball Joint Casing Layout for Stable Bearing Fixation
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Solution Overview
Problem
Existing ball joints face challenges with reduced contact area between the casing and other parts, limited design freedom, and increased size due to caulking methods, leading to unstable structures and higher costs.
Innovation Solution
A ball joint design where the caulking portion is formed inward of the casing, increasing the contact area and allowing for stable fixation while maintaining the existing layout, and enhancing design flexibility by incorporating a protruded caulking portion and elastically-deformable grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the caulking portion is formed on the outer circumferential surface of the casing to fix the bearing, then the bearing can be axially fixed, but the contact area between the casing and other part is reduced
Solution Approach 1:
The caulking portion is formed inside the casing rather than on the outer surface, nesting the fixation mechanism within the existing structure. This allows the bearing to be axially fixed through the caulking portion while preserving the full outer surface area of the casing for contact with other parts, thereby resolving the contradiction between fixation stability and contact area.
2Stability of the object's composition
If the caulking portion is formed on the outer circumferential surface of the casing, then the bearing can be fixed, but the design freedom of dust cover and mounting layout is limited
Solution Approach 1:
By nesting the caulking portion inside the casing, the outer surface of the casing remains free and unobstructed. This provides full design freedom for the dust cover and mounting layout, as the fixation mechanism no longer occupies or constrains the external geometry of the casing.
3Stability of the object's composition
If the ball seat is located higher than the end portion of the casing due to caulking, then the bearing can be fixed, but the size of dust cover and length of ball stud must be increased
Solution Approach 1:
The caulking portion is nested inside the casing, allowing the ball seat to be positioned at or near the end portion of the casing without being elevated by external caulking. This maintains a compact overall length of the ball stud and eliminates the need for an oversized dust cover.
Data Source
AI summary
The present disclosure provides a ball joint including: a ball stud having a ball portion of a spherical shape formed partially in a longitudinal direction of the ball stud; a bearing configured to surround the ball portion of the ball stud while being in a slidable contact with the ball portion; a cylindrical casing into which the ball stud and the bearing are inserted; a dust cover configured to seal an opening of the casing; and a caulking portion formed inward of the casing to fix the bearing. In the ball joint, the caulking portion is formed inward of the casing to axially fix the bearing, which increases a contact area on which the casing is brought into contact with other part, ensures a stable fixation, improves a degree of freedom in design while maintaining the layout as it is.