Bearing Shell Plastic Extension Deformation for Ball Joint Assembly
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Solution Overview
Problem
The existing manufacturing methods for bearing shell assemblies in ball joints, particularly those produced as integral injection molded plastic parts, are complex and costly due to the need for latching elements and notches, which complicate the injection molding process and increase production effort.
Innovation Solution
A method involving the production of a bearing shell with a plastic extension that is deformed to securely fasten a spring element, eliminating the need for complex latching elements by using a hollow cylindrical extension that can be easily deformed to capture the spring element, thereby simplifying the assembly process and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If latching elements with notches and detent arms are used to connect the spring element to the bearing shell, then a secure connection is achieved, but the injection molding process becomes complex and production effort increases
Solution Approach 1:
The patent extracts the latching mechanism from the injection molded bearing shell and replaces it with a simple deformation process applied after molding. The extension element is molded without complex notches or detent arms, then deformed separately to create the latching function, thereby simplifying the injection molding process while maintaining connection security
Solution Approach 2:
The extension element is prepared in advance during injection molding as a simple cylindrical structure without complex features. The latching function is created afterward through deformation, separating the molding process from the connection creation process and simplifying manufacturing
2Reliability
If latching elements with detent arms and noses are provided on the bearing shell, then a reliable connection with the spring element is achieved, but the production cost increases
Solution Approach 1:
The patent uses a simple, inexpensive extension element that is deformed to create a permanent latching connection. The deformation process creates a cost-effective solution compared to precision-molded latching elements with multiple features, reducing production costs while maintaining reliable connection
Solution Approach 2:
The patent changes the physical state and geometry of the extension element through deformation, transforming it from a simple cylindrical shape to a latched configuration. This parameter change creates a reliable connection without requiring complex molded features or additional components
3Reliability
If complex latching elements are molded into the bearing shell, then the spring element can be securely positioned, but the assembly process becomes more complex
Solution Approach 1:
The patent segments the connection creation process from the molding process. The extension element is molded separately without latching features, then deformed afterward to create the connection. This segmentation simplifies both the molding and assembly processes while ensuring secure spring element positioning
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 method allows for a cost-effective, low-effort assembly of bearing shell and spring elements with a secure, non-releasable connection, enhancing the manufacturing efficiency and reducing the complexity of the injection molding process while ensuring a reliable and durable ball joint assembly.
Implementation Method 1
the spring element is fastened to the bearing shell by cold deformation of the plastic extension
Data Source
AI summary
A method for manufacturing a bearing shell assembly for a ball joint includes the following steps: a) a bearing shell having a plastic extension is produced; b) a spring element is arranged in a region of the plastic extension; and c) the spring element is fastened to the bearing shell by deformation of the plastic extension. The invention further relates to a bearing shell assembly for a ball joint, including a bearing shell and a spring element, the spring element being non-detachably connected with the bearing shell.