Cold Formed Ball Joint Housing for Sealing Reliability
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Solution Overview
Problem
Existing ball joint manufacturing methods are inefficient, requiring significant material, energy, and time, with potential issues in sealing and durability due to deformation affecting the sealing bellows and increased risk of moisture and dirt penetration.
Innovation Solution
A ball joint with a housing produced entirely by cold forming, eliminating cutting and waste, featuring a deformed section for closure that optimizes contact with the joint ball, and a bearing shell with varying cross-sections for enhanced load capacity and reduced wear, along with an anti-twist device for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing opening is deformed to fix the ball pivot, then the ball pivot is prevented from detaching, but the deformation extends into the sealing bellows contact area and endangers the tight fit
Solution Approach 1:
The housing is divided into distinct functional zones: a deformation zone for fixing the ball pivot and a separate sealing zone for the sealing bellows. The sealing zone is designed with sufficient radial distance from the deformation zone, ensuring that deformation forces do not compromise the sealing contact area. This spatial segmentation allows independent optimization of fixing strength and sealing reliability.
Solution Approach 2:
Different regions of the housing are designed with different geometric properties tailored to their specific functions. The deformation zone has geometry optimized for forming and fixing the ball pivot, while the sealing zone maintains precise cylindrical geometry for optimal sealing bellows contact. This local differentiation ensures each area performs its function without interfering with the other.
2Ease of manufacture
If traditional manufacturing methods with cutting and covering are used, then the housing can be assembled, but the production process is complex and time-consuming
Solution Approach 1:
Multiple housing functions are merged into a single integrated structure: the housing body, the ball pivot fixing mechanism, and the sealing bellows mounting area are all formed as one piece through cold forming. This eliminates the need for separate covering components and assembly steps, significantly simplifying manufacturing while maintaining all necessary functions. The single-piece design reduces part count and assembly complexity.
Solution Approach 2:
The housing is pre-formed with all necessary geometric features during the cold forming process, including deformation zones for ball pivot fixation and precise contact areas for sealing bellows attachment. This preliminary formation of functional features eliminates the need for subsequent assembly operations, thereby increasing production efficiency without compromising ease of manufacture.
3Shape
If material is removed through cutting, then the housing shape is achieved, but significant material waste is generated
Solution Approach 1:
The manufacturing approach transitions from subtractive (cutting) to formative (cold forming) processes. By changing the fundamental manufacturing parameter from material removal to material displacement, the housing achieves its final geometry through plastic deformation of the blank into the desired shape. This parameter change eliminates material waste while maintaining precise geometric control.
Solution Approach 2:
The excess material that would normally be wasted during cutting operations is instead utilized as a resource for forming the housing shape through cold forming. The material displacement during forming creates the necessary geometry without generating waste, effectively converting what would be a harmful loss into a beneficial forming mechanism.
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 significantly reduces production costs, ensures a reliable seal, and enhances the load-bearing capacity and durability of the ball joint by minimizing deformation impact on the sealing bellows and optimizing contact areas.
Implementation Method 1
A ball joint with a housing (1) produced overall by a cold forming process
Implementation Method 2
a contact area (7) present on the outer lateral surface (27) of the housing for sealing attachment of a sealing bellows edge (8)
Implementation Method 3
a bearing shell (13) inserted into the interior (4) of the housing, which accommodates the joint ball (2)
Data Source
Figure 1
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AI summary
The invention relates to a ball joint having a housing (1) produced overall by a cold forming method, comprising an interior space (4) that is adapted for mounting the joint ball (2) of a ball pin (3) and, on one side, comprising an opening (5) for passing through the pin section (6) of the ball pin (3) connecting to the joint ball (2), a contact region (7) present on the outer lateral surface of the housing (1) for sealingly fastening a bellows seal edge (8), and a deformation section (9) of the housing (1) for the rotatable and pivotable fixation of the joint ball (2) of the ball pin (3) in the interior space (4). According to the invention, the material displaced during the cold forming process forms the deformation section (9) of the housing (1) after the housing (1) is finished. The claimed method for producing a ball joint is characterized by the following steps: - producing a metal housing blank (25) having a thickening (26) integrally formed by way of upsetting, - configuring the housing outer contour (27) by way of upsetting, - forming the housing inner contour (28) by way of can extrusion, wherein the displaced material is used in particular for configuring the deformation section (9).