Folded Sheet Metal Knuckle Protector for Thermal Management
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Solution Overview
Problem
Existing ball joint protection devices in vehicles are costly to manufacture and prone to deformation due to high temperatures from brake discs, which can damage the elastomer rubber bellows.
Innovation Solution
A protective device comprising an annular flange and a heat shield formed in one piece from a folded sheet metal, with a slot-shaped indentation separating the lateral wing from the flange, allowing for a simpler and less expensive manufacturing process and enhanced resistance to deformation through locking means and reinforcing ribs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a large flange is placed between the brake disc and the ball joint to protect against high temperatures, then thermal protection is improved, but manufacturing cost and material consumption increase
Solution Approach 1:
The protective device is segmented into distinct functional zones: an annular flange for mounting, a heat shield extending perpendicular to the flange, and lateral flanges extending along the annular periphery. This segmentation allows each zone to be optimized for its specific function while using less material overall compared to a single large flange design.
Solution Approach 2:
The protection structure extends in multiple dimensions: the heat shield extends in height perpendicular to the flange, while lateral flanges extend along the annular periphery. This multi-dimensional approach provides comprehensive thermal protection without requiring excessive material in any single dimension.
2Strength
If a deep drawing operation is used to form the flange and heat shield in one piece from metal sheet, then structural integrity is improved, but manufacturing time and energy consumption increase
Solution Approach 1:
The manufacturing process is segmented into distinct operations: cutting the metal sheet to shape, folding along predetermined lines to form the annular flange, heat shield, and lateral flanges, and finally assembling by securing to the ball joint. This segmentation allows each operation to be simple and rapid, avoiding the need for complex multi-pass deep drawing while maintaining structural integrity through precise folding lines and assembly features.
3Stability of the object's composition
If the screen and flange are formed in one piece with a long connection zone, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The connection between the screen and flange is achieved through a standardized mounting arrangement with securing means positioned at specific locations around the annular flange. This segmented approach provides sufficient structural stability while keeping the manufacturing process simple and repeatable, avoiding the complexity of long continuous connection zones.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a protection device (1) for a knuckle joint (21) e.g. for the steering and/or suspension of a vehicle, which comprises an annular flange (2) for securing a thermal screen (3) to the knuckle joint, said screen extending lengthwise substantially perpendicular to the flange (2) and widthwise substantially along the annular periphery of the flange. The screen and the flange are formed as a single part in a metal sheet that is folded in a linking area between the screen and the flange, the screen further including a surface portion in the form of a side tab (6) extending along the annular periphery of the flange, said side tab being separated from the flange by a notch (12) in the metal sheet, in the form of a slot.