Hollow Chassis Component With Molded Joint Housing Interlock

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Solution Overview

Problem

Existing chassis components require additional steps and materials to create a hole for interlocking with plastic joint housings, which increases costs and predetermines the orientation of the base body, while using solid bars as an alternative increases weight.

Innovation Solution

A hollow metallic base body with deformed end sections featuring ridges and depressions is used, allowing for plastic joint housings to be injection-molded or cast onto the base body without needing specific orientation, while maintaining a strong interlock and reducing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a through-going hole is made in the end section to achieve interlock with plastic joint housing, then sufficient interlock is realized, but additional cost and work step are required

Engineering Contradiction:

Improveinterlock between joint housing and base bodyVSAvoidproduction complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the sealing function and the interlocking function into a single integrated structure. The deformed end section creates both the seal (by closing the hollow base body) and the interlocking features (ridges and depressions) in one operation, eliminating the need for separate hole-making steps while achieving both sealing and secure plastic injection-molding attachment.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If the end section is formed as a flat profile with a hole to enable interlock, then sufficient interlock is achieved, but the direction and orientation of the joint housing relative to the base body is predetermined

Engineering Contradiction:

Improveinterlock between joint housing and base bodyVSAvoidorientation flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The deformed end section creates a rotationally symmetric or multi-directional interlocking structure with ridges and depressions that can engage with the joint housing from multiple orientations. This universal design allows the joint housing to be positioned in different directions and orientations relative to the base body while maintaining secure interlock, eliminating the need for predetermined orientation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If a bar made of solid material is used as base body to avoid orientation requirements, then orientation flexibility is achieved, but the weight increases compared with a tubular base body

Engineering Contradiction:

Improveorientation flexibilityVSAvoidweight of base body

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent applies local quality by creating a hollow tubular base body for weight reduction, and only locally deforming the end section to create the interlocking structure. This allows the majority of the base body to remain lightweight and hollow, while the end section gains the necessary structural features for multi-directional attachment without requiring the entire base body to be solid material.

Inventive Principle:

Principle #3Local quality

4Reliability

If additional steps are taken to create a hole for interlocking, then sufficient interlock is achieved, but production time and complexity increase

Engineering Contradiction:

Improveinterlock strengthVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The interlocking features (ridges and depressions) are created during the initial deformation process of the end section, before the plastic injection-molding step. This preliminary formation of interlocking structures eliminates the need for subsequent hole-making operations, streamlining the production process and improving efficiency while ensuring strong interlock.

Inventive Principle:

Principle #10Preliminary action

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 process optimizes production by integrating ridges and depressions in a single step, ensuring a secure interlock and sealing without additional weight, thus reducing material usage and production complexity.

Implementation Method 1

at least one axial end section of the base body is deformed so as to seal the base body

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

the at least one joint housing made of plastic is injection-molded and/or cast onto the end section of the base body

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS12447785B2Chassis component for a vehicle with a hollow metal base body and method of manufacturing such a chassis component

Publication Date: 2025.10.21 ZF FRIEDRICHSHAFEN AG

AI summary

A chassis component for a vehicle has a hollow metallic base body, where at least one axial end section of the base body is deformed in order to seal the base body, and having at least one joint housing made of plastic. The joint housing is injection-molded and/or cast onto the end section of the base body. In order to produce in a simple manner a sufficient interlock between the plastic of the joint housing and the end section, an outer side of the end section has a number of ridges and depressions such that by means of the ridges and depressions an interlock can be formed with the plastic of the joint housing.