Carbon Fiber Composite Kinematic Pair for Low-Angle Precision
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Solution Overview
Problem
Conventional ball joints have multiple parts, leading to production-related deviations and varying compression between bearings, resulting in inconsistent stiffness and limited design flexibility for angles less than 30°.
Innovation Solution
A housing element made from carbon fiber composite materials with a braided texture, featuring a pre-tensioned structure and a graphite-based coating for reduced friction, allowing for precise and strong kinematic pairs with rotational and sliding movements, including ball and socket joints with angles as low as 5°.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ball joint is assembled with multiple parts (inner bearing, outer bearing, biasing element, folded rim), then the structure can provide compression and stiffness, but the production-related deviations in shape and size lead to varying compression and inconsistent performance
Solution Approach 1:
The patent merges multiple separate components (inner bearing, outer bearing, biasing element, folded rim) into a single integrated housing element made of carbon fiber composite material. This monolithic structure eliminates the accumulation of manufacturing deviations that occur when assembling multiple parts, ensuring consistent compression and stiffness while maintaining the necessary mechanical functions.
Solution Approach 2:
The patent uses carbon fiber composite material with braided texture to create the housing element. This composite material provides both the necessary strength for compression and stiffness while allowing for precise manufacturing with consistent dimensions, thereby achieving uniform compression across all produced joints without the variability inherent in multi-part metal assemblies.
2Stability of the object's composition
If the outer rim is folded inside towards the center of the socket opening to secure the outer bearing, then the bearing is kept in place, but the compression of the ball varies for every ball joint due to limiting folding accuracy
Solution Approach 1:
The housing element integrates the functions of the folded rim and outer bearing retention into a single molded structure. The carbon fiber composite housing is formed with an integrated geometry that secures the ball and bearing assembly without requiring separate folding operations, thereby eliminating the compression variability caused by manual or automated folding processes.
3Strength
If a traditional metal housing is used for the ball joint, then the structure provides sufficient strength, but the weight is high and the design flexibility for angles less than 30° is limited
Solution Approach 1:
The patent replaces traditional metal housing material with carbon fiber composite material. This composite material has a high strength-to-weight ratio, providing sufficient structural strength while significantly reducing the weight of the housing element. The material properties of carbon fiber composites enable both lightweight construction and the structural integrity required for ball joint applications.
Solution Approach 2:
The use of carbon fiber composite material changes the physical parameters of the housing, particularly the density and strength characteristics. This material substitution enables the housing to be both lighter and stronger than traditional metal constructions, while also allowing for greater design flexibility in achieving small angles less than 30° due to the material's formability and structural properties.
4Ease of manufacture
If conventional ball joints are designed with multiple separate components, then assembly is possible, but the number of parts increases device complexity and reduces design flexibility
Solution Approach 1:
The patent combines multiple separate components (housing, bearings, biasing element, retention mechanism) into a single integrated housing element made of carbon fiber composite material. This reduces the total number of parts and simplifies the assembly process, as the monolithic housing is designed to accommodate and secure all internal components in a single assembly operation, thereby reducing device complexity while maintaining ease of manufacture.
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 carbon fiber composite structure provides a strong, lightweight, and precise kinematic pair with even tension distribution, enabling greater freedom of movement and reduced friction, overcoming the limitations of prior art in terms of stiffness and design flexibility.
Implementation Method 1
This structure also has a pre-tension which means that there is no play or backlash between the housing element and the engagement element
Implementation Method 2
The coating element makes sure that the engagement element may rotate and/or slide freely without unnecessary friction; it provides even better anti-friction properties
Data Source
AI summary
A kinematic pair (10), e.g. a ball and socket joint, with at least a housing element (30) and an engagement element (20) where the engagement element (20) is arranged at least partly within the housing element (30) and configured to achieve a rotational and/or sliding movement relative the housing element (30). The housing element (30) is designed with at least one first carbon fiber composite material layer surrounding at least a part of the engagement element, a carbon fiber composite material wrapping arranged around at least a part of the first layer, and at least one second carbon fiber composite material layer arranged on the outside of the wrapping.