Composite Ball Joint Structure for Lower Weight and Machining Cost
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Solution Overview
Problem
Conventional ball joints used in vehicles are heavy, leading to reduced energy efficiency and high production costs, particularly for large quantities, due to their metal construction and complex machining requirements.
Innovation Solution
The ball stud is composed of an elongated metallic part with integrated plastic shells forming a spherical thickening, reducing weight by using plastic instead of metal for the spherical portion, and allowing separate manufacturing of parts for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ball stud is manufactured as a single-piece metal component, then structural integrity and load-bearing capacity are ensured, but weight becomes excessively high
Solution Approach 1:
The ball stud is divided into multiple components: a metal core element (stud part) and separate plastic shell elements. The metal core provides structural strength while the plastic shells form the spherical bearing surface. This segmentation allows each material to be used where it is most effective, reducing overall weight while maintaining integrity.
Solution Approach 2:
The ball joint uses a composite structure combining metal and plastic materials. The metal core element provides mechanical strength and load-bearing capacity, while the plastic shell elements provide the spherical bearing surface with lower density. This composite approach achieves weight reduction while preserving structural integrity.
2Manufacturing precision
If the ball stud is manufactured as a single-piece metal component, then manufacturing precision can be maintained, but production cost and environmental impact increase due to extensive machining
Solution Approach 1:
The manufacturing process is segmented into separate steps for the metal core and plastic shells. The metal core can be produced by cost-effective processes such as forging or rolling, while the plastic shells are manufactured separately using injection molding. This segmentation eliminates the need for expensive and environmentally damaging machining of large-diameter metal blanks.
Solution Approach 2:
The traditional mechanical machining process for creating the spherical surface is replaced by a combination of metal core fabrication and plastic shell molding. The plastic shells are formed through injection molding processes that naturally create the required spherical geometry without extensive material removal, significantly reducing production costs and environmental impact.
3Weight of moving object
If plastic shells are used to form the spherical thickening, then weight is reduced, but the complexity of assembling multiple parts increases
Solution Approach 1:
The plastic shells are designed to be mounted on the metal core element in a way that merges their functions with the core. The shells not only form the spherical bearing surface but also integrate with the core structure to provide structural support. This merging reduces the functional complexity that would otherwise require separate components.
Solution Approach 2:
The metal core element acts as an intermediary that connects and integrates the plastic shells. The core provides a unified structural foundation that simplifies the assembly of multiple plastic shells, as they can be mounted on the pre-formed core rather than being assembled separately. This intermediary structure reduces overall assembly complexity.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a ball joint, particularly for vehicles, comprising a ball stud (1) as the inner bearing part and as the first bearing part, wherein the ball stud (1) has a spherical part (17) as a convex thickening and a connecting clamp projecting from the spherical part (17) or two connecting clamps (5, 6) projecting opposite each other from the spherical part (17), comprising a bearing housing (26) as the second bearing part, which surrounds the spherical part (17), and comprising at least one elastomer element (22) arranged under preload between the spherical part (17) and the bearing housing (26), which encompasses the spherical part (17). According to the invention, the ball stud (1) has an elongated, metallic stud part (3) that forms the one connecting clamp or the two connecting clamps (5, 6), as well as a spherical inner part (4) adjoining it in one piece and of a single material.To form the spherical part (17), two plastic half-shells (12, 13) are attached to the metallic inner sphere part (4), forming a convex thickening (13), wherein the two plastic half-shells with half-shell edges (14, 15) lie against each other at a parting plane (16) and are positively engaged at the outer contour of the inner sphere part (4) with a shell inner contour as a counter contour, thereby enclosing the inner sphere part (4) with the convex thickening (13) lying transversely to the clamp direction.