Ball Joint Compression Ring Structure for High-Load Durability

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Solution Overview

Problem

Conventional ball joint assemblies face durability issues under high load conditions, leading to reduced lifespan and increased maintenance costs, which can compromise vehicle safety and control.

Innovation Solution

A ball joint assembly design featuring a ball stud with a spherical and tapered portion, a ring with a ring projection for press-fitting into a housing, and a seat with vertical and horizontal lubrication channels for improved stress distribution and friction reduction, eliminating the need for thermal refinement steps in manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional ball joint assemblies are used under high load conditions, then the assembly can function initially, but durability and lifespan are reduced due to wear and stress concentration

Engineering Contradiction:
ImprovedurabilityVSAvoidlifespan
Core Design Contradiction:
ReliabilityVSDuration of action of moving object

Solution Approach 1:

The patent applies local quality by creating a dual-density ring structure where the first portion has a first density and the second portion has a second density different from the first. This density variation is strategically positioned to distribute stress locally - the denser portion handles high-stress compression zones while the less dense portion manages tension zones, preventing uniform wear and extending component lifespan under high load conditions.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent employs composite materials through the dual-density ring design, combining two materials or material states with different densities within a single component. This composite structure allows the ring to simultaneously exhibit properties of both dense and less dense materials in different regions, optimizing both durability under compression and flexibility under tension, thereby resolving the contradiction between initial functionality and long-term durability.

Inventive Principle:
Principle #40Composite materials

2Reliability

If thermal refinement steps are used in manufacturing ball joints, then friction reduction is achieved, but manufacturing complexity and costs increase

Engineering Contradiction:
Improvefriction reductionVSAvoidmanufacturing process simplicity
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces thermal refinement processes with a mechanically formed dual-density ring structure. Instead of using heat treatment or thermal refinement to reduce friction, the invention achieves low-friction performance through the inherent properties of the dual-density configuration, where the material composition and structural design naturally minimize friction during operation, thereby simplifying the manufacturing process while maintaining reliability.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies parameter changes by fundamentally altering the density parameter of the ring material rather than using thermal processes. By changing the density distribution from uniform to dual-density, the patent achieves friction reduction through material parameter optimization instead of thermal refinement, simplifying manufacturing while maintaining or improving performance.

Inventive Principle:
Principle #35Parameter changes

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 design enhances durability and lifespan by ensuring uniform stress distribution and reduced friction, resulting in improved performance under high load conditions and simplified manufacturing.

Implementation Method 1

a ring for mounting between the seat and a housing of the ball joint assembly to press-fit high load to the seat

Methodology Applied
Scientific EffectElastic deformation: Elasticity

Implementation Method 2

The seat may further include a plurality of vertical lubrication channels

Methodology Applied
Scientific EffectLubrication: Lubrication

Data Source

PatentUS11215221B1Ball joint assembly and method of assembly and ball joint compression ring
Publication Date: 2022.01.04 MUSASHI AUTO PARTS CANADA INC
  • US11215221B1 patent drawing
  • US11215221B1 patent drawing
  • US11215221B1 patent drawing

AI summary

A ball joint assembly, a ring for use in a ball joint assembly, a seat for use in a ball joint assembly, and a method of assembly a ball joint are provided. The ball joint assembly includes a ball stud with a spherical portion and a tapered portion, wherein the spherical portion is positioned in a seat. The ring is formed as an annulus shape and includes a ring projection positioned at an outer surface of the ring, the ring for mounting between the seat and a housing of the ball joint assembly to press-fit high load to the seat. The ball joint assembly includes a seat for attaching to the ball stud at the spherical portion and to support the ring with high stress. The seat includes a seat projection comprising a portion of the seat extending beyond an outer surface of the seat towards the housing.