Ball Socket Exit Bearing With Metal Insert for Axial Load Support
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Solution Overview
Problem
Existing ball joint socket assemblies face challenges in supporting heavy negative axial loads without increasing manufacturing costs or restricting stud movement, particularly when using plastic bearings that expand under load.
Innovation Solution
A ball socket assembly featuring an overmolded connection between a plastic and metal piece, where the metal piece is semi-conical and embedded within the plastic, with angled and cylindrical surfaces to support the ball stud, and a housing deformation to capture the exit bearing, allowing for enhanced force transfer and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cross-sectional size of the metallic cover plate is increased to support heavy negative axial loads, then the strength to support large negative axial loads is improved, but the manufacturing cost increases and stud swing may be restricted
Solution Approach 1:
The exit bearing is constructed as a composite component with a metal insert embedded in plastic material. The metal insert (semi-conical or conical shape) provides the necessary strength to handle heavy negative axial loads, while the plastic material provides bearing surface for the ball stud. This composite structure achieves the required load-bearing capacity without increasing the overall size or thickness of the cover plate, thereby avoiding increased manufacturing costs and restriction of stud swing.
2Strength
If the strength type of metal of the cover plate is increased to support heavy negative axial loads, then the strength to support large negative axial loads is improved, but the manufacturing cost increases and stud swing may be restricted
Solution Approach 1:
The metal insert within the plastic bearing provides localized strength exactly where needed to support negative axial loads, rather than requiring the entire cover plate to be made of high-strength metal. This concentrated reinforcement approach maintains the overall flexibility and swing capability of the ball stud while providing the necessary load-bearing capacity.
Solution Approach 2:
The metal insert is positioned specifically at the rear portion of the bearing where it is needed to support axial loads. The plastic material remains at the front to provide the bearing surface for stud swing. This local differentiation of material properties allows the structure to have high strength where needed while maintaining flexibility and range of motion where required.
3Strength
If the thickness of the metallic cover plate is increased to support heavy negative axial loads, then the strength to support large negative axial loads is improved, but the manufacturing cost increases and stud swing may be restricted
Solution Approach 1:
Instead of increasing the thickness or complexity of a solid metal cover plate, the invention uses a composite bearing structure where a metal insert is embedded in plastic. This achieves the required strength-to-weight ratio and strength-to-size ratio without increasing overall component thickness or structural complexity.
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
This configuration effectively supports increased forces while maintaining the structural integrity and reducing the risk of plastic deformation, thereby optimizing the ball joint's performance under heavy loads without increasing manufacturing costs or restricting stud movement.
Implementation Method 1
The exit bearing includes a plastic piece and a metal piece which are in an overmolded connection with one another
Implementation Method 2
the plastic material can expand under load due to a contact angle between the bearing and the ball stud
Implementation Method 3
The housing is deformed adjacent the at least one open end to capture the exit bearing within the inner bore
Data Source
AI summary
One aspect of the present invention is related to a ball socket assembly that includes a housing with an inner bore and at least one open end. The ball socket assembly also includes a ball stud which is partially received in the inner bore of the housing. An exit bearing supports the ball stud and is positioned in the inner bore adjacent the at least one open end. The exit bearing includes a plastic piece and a metal piece which are connected with one another. The metal piece has a semi-conical shape. The housing is deformed adjacent the at least one open end to capture the exit bearing within the inner bore. In operation, the metal piece reinforces the plastic piece to transfer forces between the ball stud and the housing.