Ball Stud Joint Sleeve Assembly for Minimal Lateral Clearance
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Solution Overview
Problem
Existing ball joints in vehicle suspensions face issues with lateral clearance, particularly when subjected to axial and lateral loads, leading to loosening and potential damage, especially when mating components have different material densities.
Innovation Solution
A ball stud assembly with a deformable sleeve that fills the gap between the stepped bore and shank shape, minimizing lateral clearance by shifting and deforming to accommodate machining variations and material differences, using a threaded nut to tighten and secure the joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional ball joint with fixed clearance is used, then the joint allows movement in multiple directions, but lateral clearance increases under axial and lateral loads causing loosening and potential damage
Solution Approach 1:
The ball stud shank features a stepped configuration with two different diameter sections, allowing the joint to dynamically adapt its clearance characteristics. The first section (closer to the ball) has a larger diameter than the second section, creating variable lateral clearance that can accommodate movement while maintaining stability under load.
Solution Approach 2:
Different sections of the ball stud shank have different diameters to provide localized functionality. The first shank section has a larger diameter for initial engagement and load distribution, while the second section has a smaller diameter to reduce lateral clearance and prevent loosening under axial and lateral loads.
2Adaptability or versatility
If machining variations and material density differences are accommodated, then the joint can work with different materials, but lateral clearance increases leading to loosening
Solution Approach 1:
The stepped shank design changes the dimensional parameters of the ball stud, creating two distinct diameter sections that can accommodate machining variations and material density differences while controlling lateral clearance through the transition between sections.
3Shape
If the ball stud is tightly fitted to minimize clearance, then lateral clearance is reduced, but the joint becomes difficult to assemble and accommodate dimensional variations
Solution Approach 1:
The ball stud shank is segmented into two distinct diameter sections, allowing the joint to be assembled with the larger first section providing initial clearance tolerance, while the smaller second section provides the tight fit for minimizing lateral clearance under operating conditions.
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 solution effectively reduces the likelihood of joint loosening and maintains structural integrity under service loads, even with lower density materials, by minimizing lateral clearance and accommodating dimensional variations.
Implementation Method 1
deform the sleeve in the gap between the stepped bore and the stepped shape shank such that the sleeve fills at least part of the gap
Implementation Method 2
A ball stud assembly with a deformable sleeve that fills the gap between the stepped bore and shank shape, minimizing lateral clearance by shifting and deforming to accommodate machining variations and material differences
Implementation Method 3
threaded nut configured to engage the threaded second end to tighten the ball stud on the component
Data Source
AI summary
A ball stud assembly includes a ball stud for engaging a component with a stepped bore extending along a bore axis and a reaction surface orthogonal to the bore axis. The stud includes a ball first end, a threaded second end, and a flange. The stud additionally includes a shank extending along a stud axis between the first and second ends, having a stepped shank shape, and configured to extend through the stepped bore and leave a gap between the bore and the shank. The stud also includes a flange between the first end and the shank with a flange surface orthogonal to the stud axis for engaging and abutting the reaction surface. The stud additionally includes a sleeve positioned on the shank and a threaded nut configured to tighten the stud on the component and deform the sleeve such that the sleeve fills at least part of the gap.