Blind Boss Ball Socket Assembly for Multi-Diameter Stud Retention
Solution Overview
Problem
Existing ball socket connection systems for lamp assemblies face challenges in retaining ball studs with smaller diameters, especially under conditions of increased off-axis rotation, elevated temperatures, and higher retention forces required for LED systems. Additionally, these systems struggle with assembly into blind boss mating geometries.
Innovation Solution
A multi-stage ball socket assembly is introduced, featuring a ball socket with a socket base, socket legs, slots, a lower abutment wall, and a flexible securing substrate with tangs. This assembly interacts with a mating boss substrate having different inner passages and a transition wall, allowing for controlled resistance and alignment during assembly, thereby enhancing retention and accommodating various ball diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional ball socket designs are used, then assembly is simple, but retention force is insufficient for smaller ball diameters and LED systems
Solution Approach 1:
The patent utilizes elastic deformation of the securing substrate to change the mechanical parameters of the ball socket. During assembly, the substrate deforms elastically to allow insertion of ball studs with various diameters. After assembly, the elastic recovery provides enhanced retention force, resolving the contradiction between accommodating different ball sizes and maintaining strong retention.
Solution Approach 2:
The ball socket transitions from a static rigid structure to a dynamic flexible structure. The securing substrate can deform during assembly to accommodate different ball diameters, then maintains a constrained state to provide retention force. This dynamic behavior allows the same structure to adapt to various ball sizes while maintaining strong retention.
2Force
If lock-edges or undercuts are added to increase retention, then axial pull resistance improves, but off-axis rotation capability is restricted
Solution Approach 1:
The patent replaces rigid lock-edges and undercuts with a flexible securing substrate. This flexible structure can deform to accommodate off-axis rotation movements while maintaining axial retention through elastic recovery. The substrate acts as a compliant locking mechanism that allows the ball socket to rotate off-axis without the restriction caused by rigid geometric features.
3Force
If rigid securing structures are used, then retention is strong, but assembly into blind boss geometries is difficult
Solution Approach 1:
The securing substrate undergoes elastic deformation during assembly to adapt to blind boss geometries. The material properties allow the structure to temporarily change shape for easy insertion, then recover to provide strong retention. This elastic parameter change enables assembly into challenging blind boss configurations while maintaining strong securing force.
Solution Approach 2:
The flexible securing substrate acts as a cushioning element during assembly. It can deform to absorb assembly misalignments and accommodate variations in blind boss geometries, making assembly easier. After assembly, the substrate maintains its structural integrity to provide strong retention, effectively cushioning the assembly process while ensuring strong final retention.
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 multi-stage ball socket assembly provides improved retention of ball studs across multiple diameters, even at increased off-axis rotation, while allowing for easy insertion and assembly into blind boss geometries, thus addressing the limitations of existing systems.
Implementation Method 1
a flexible securing substrate having a plurality of tangs and positioned under the lower abutment wall and substantially centered about the bend line
Data Source
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Figure 3~4
Figure 5~6
AI summary
A ball socket assembly is provided that includes a ball socket having a socket base with a plurality of socket legs extending therefrom, the socket legs include ball stud interface surfaces forming a ball cavity for receiving and selectively engaging a ball head of a ball stud, a plurality of slots extending between the plurality of socket legs, a lower abutment wall having a bend line and situated in the socket base, and a flexible securing substrate positioned under the lower abutment wall, the socket assembly further including a mating boss substrate having a first boss inner passage with a first passage inside diameter, a second boss inner passage having a second passage inside diameter, wherein the first passage inside diameter is greater than the second passage inside diameter, a boss transition wall between the first boss inner passage and the second boss inner passage, and a boss bottom.