One-Piece Linkage Assembly with Insert Molded Pins
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Solution Overview
Problem
Traditional articulating linkage assemblies for vehicle applications are made of multiple separate pieces, which can expose metal pivot pins to the outside environment, increasing the risk of corrosion and requiring more components and assembly steps.
Innovation Solution
A one-piece insert molded articulating linkage assembly where metal pivot pins are encased in polymer material composition, reducing exposure to the environment and integrating multiple components into a single molded piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-piece linkage assemblies are used, then the assembly process requires multiple separate components and assembly steps, but this increases the complexity of the device and exposes metal pivot pins to the outside environment
Solution Approach 1:
The patent merges multiple separate linkage components into a single integrated polymer linkage body through injection molding. The metal pivot pins are embedded within the polymer material, combining what were previously separate components (linkage members, bushings, and pivot pins) into one unified structure. This eliminates the need for separate bushings to protect the pivot pins, as the polymer material itself provides the protective enclosure.
2Ease of manufacture
If multiple separate components are used in the linkage assembly, then each component can be individually manufactured, but this increases the number of assembly steps and manufacturing complexity
Solution Approach 1:
The metal pivot pins are pre-positioned and embedded within the polymer material during the injection molding process itself. The molding cavity is designed to hold the pivot pins in their final positions, and the polymer is injected around them to create the finished linkage assembly in a single manufacturing step. This preliminary positioning and integration eliminates the need for subsequent assembly steps where pivot pins would otherwise need to be installed separately.
3Strength
If metal pivot pins are exposed to the outside environment, then the linkage assembly can be simpler in structure, but this increases the risk of corrosion and reduces durability
Solution Approach 1:
The patent creates a composite structure where metal pivot pins are embedded within a polymer matrix. The polymer material (such as nylon or polyethylene) provides corrosion resistance and environmental protection to the metal pivot pins, while the metal pins provide the necessary mechanical strength and low-friction rotational surfaces. This composite construction allows the metal pins to function effectively without direct exposure to corrosive environmental factors.
Data Source
AI summary
A one-piece linkage assembly (20) includes a linkage base (120, 122, 22) for securement to a structure and a linkage follower (124, 24) fixed to the linkage base (120, 122, 22) with a stainless steel first pivot pin in a hinged configuration. The linkage base (120, 122, 22) and the linkage follower (124, 24) each are made of a molded material, such as plastic, and are formed together with the first metal pivot pin (126, 130, 132, 136, 26, 32, 36) insert molded there between. A linkage coupler (130, 30) and a linkage drive (134, 34) are similarly pivotably secured to the linkage follower (124, 24) in a chained configuration and are also made of the molded material and are formed together with the linkage base (120, 122, 22) and the linkage follower (124, 24), with additional stainless steel pivot pins insert molded between the linkage follower (124, 24) and the linkage coupler (130, 30) and between the linkage coupler (130, 30) and the linkage drive (134, 34). Compression limiters (146, 46) are also insert molded within a flat portion (142, 42) of the linkage base (120, 122, 22).