Ball Socket Dust Boot Annular Metal Ring Seal
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Solution Overview
Problem
Existing ball socket assemblies and dust boots face issues such as non-uniform, wavy outer surfaces due to metal annuli, which compromise the seal and are costly to manufacture, leading to assembly complications and an unsightly appearance.
Innovation Solution
A ball socket assembly with a dust boot featuring a flexible tubular wall and an annular metal ring that encapsulates the annular flange, providing a uniform, aesthetically pleasing appearance and a secure seal without the need for machined grooves, using an annular metal ring with a cylindrical wall, base, and lip to facilitate assembly and prevent a wavy outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal annulus with retention teeth is used to fix the dust boot to the housing, then the dust boot can be securely attached, but the outer surface of the dust boot becomes non-uniform and wavy
Solution Approach 1:
An annular metal ring is introduced as an intermediary component between the dust boot and the housing. This ring has a smooth outer surface that does not create waves, while its inner structure includes retention teeth that engage with the housing to provide secure attachment. The metal ring acts as a mediator that separates the attachment function from the aesthetic surface requirement.
Solution Approach 2:
The attachment system is segmented into three distinct components: the dust boot, the annular metal ring, and the housing. The metal ring is further segmented with retention teeth on its inner surface. This segmentation allows each component to fulfill its specific function independently - the ring provides attachment while maintaining a smooth outer surface.
2Reliability
If an annular groove is machined into the housing to receive retention teeth, then the dust boot can be fixed to the housing, but the manufacturing cost increases
Solution Approach 1:
Instead of modifying the housing by machining an annular groove (traditional approach), the invention inverts the approach by providing the retention teeth on the inner surface of the annular metal ring. This eliminates the need for costly machining operations on the housing while achieving the same attachment security.
Solution Approach 2:
The annular metal ring with pre-formed retention teeth serves as a cost-effective alternative to machining the housing. The ring can be manufactured separately using more economical processes and then assembled to the housing, reducing overall manufacturing costs.
3Ease of operation
If the upper shoulder of the dust boot is exposed during assembly, then the dust boot can be assembled to the housing, but assembly complications arise and the appearance becomes unsightly
Solution Approach 1:
The annular metal ring serves as a mediator that covers the exposed upper shoulder of the dust boot. During assembly, the metal ring is pressed onto the dust boot, and its lip extends over the upper shoulder, concealing it from view. This eliminates the unsightly appearance while facilitating a cleaner assembly process.
Solution Approach 2:
The metal ring provides localized coverage specifically at the upper shoulder region of the dust boot. The lip of the metal ring is designed to extend radially inwardly to cover only the exposed shoulder area, maintaining aesthetic appearance without affecting other functional areas of the dust boot.
Data Source
AI summary
A ball socket assembly, dust boot assembly therefor, and method of construction thereof are provided. The ball socket assembly includes a housing with an inner bore extending along a central axis. A bearing is disposed in the inner bore. A ball portion of a ball stud is disposed in sliding engagement with the bearing and a shank portion extends outwardly from the housing. A dust boot assembly having a tubular wall extends along the central axis between a distal end disposed about the shank portion and a proximal end in sealed engagement with the housing. The dust boot proximal end has an annular flange extending radially outwardly from the central axis. The annular flange has a cylindrical outer surface, a lower surface and an upper shoulder. An annular metal ring is disposed about and substantially encapsulates the cylindrical outer surface, lower surface and upper shoulder of the annular flange.