Reinforced Polymeric Socket Bearing for Relaxed Tolerances
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Solution Overview
Problem
Compression loaded socket assemblies in vehicle suspension and steering systems require tight dimensional tolerances, leading to potential damage or locking issues if components are out of tolerance, and existing solutions with looser tolerances use metal bearings, which are costly and heavy.
Innovation Solution
A socket assembly with a housing and ball stud featuring a polymeric backing bearing reinforced with a metal piece that restricts radial expansion, allowing for relaxed tolerances and weight savings while maintaining durability, using a cup-shaped reinforcement piece with annular walls and ribs, and a method of overmolding plastic with metal reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal bearings are used to allow looser tolerances, then manufacturing precision requirements are relaxed, but weight and cost increase
Solution Approach 1:
The backing bearing combines polymeric material with embedded metal reinforcement pieces (stamped steel or powdered metal). This composite structure provides the durability and tolerance accommodation of metal bearings while maintaining the weight advantages of polymer bearings. The metal reinforcement is embedded within the polymeric piece to resist radial expansion under load.
Solution Approach 2:
The reinforcement pieces are strategically embedded only in specific regions of the polymeric backing bearing where structural support is needed to resist radial expansion. This localized reinforcement approach provides metal-level durability where required while keeping the overall bearing lightweight through the use of polymer in non-critical areas.
2Weight of moving object
If polymeric bearings are used to reduce weight and cost, then manufacturing precision can be relaxed, but durability and resistance to radial expansion decrease
Solution Approach 1:
The backing bearing combines polymeric material with embedded metal reinforcement pieces (stamped steel or powdered metal). This composite structure provides the durability and tolerance accommodation of metal bearings while maintaining the weight advantages of polymer bearings. The metal reinforcement is embedded within the polymeric piece to resist radial expansion under load.
Solution Approach 2:
The reinforcement pieces are strategically embedded only in specific regions of the polymeric backing bearing where structural support is needed to resist radial expansion. This localized reinforcement approach provides metal-level durability where required while keeping the overall bearing lightweight through the use of polymer in non-critical areas.
3Reliability
If tight dimensional tolerances are required for compression loaded socket assemblies, then durability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The backing bearing combines polymeric material with embedded metal reinforcement pieces (stamped steel or powdered metal). This composite structure provides the durability and tolerance accommodation of metal bearings while maintaining the weight advantages of polymer bearings. The metal reinforcement is embedded within the polymeric piece to resist radial expansion under load.
Solution Approach 2:
The invention changes the material parameters of the backing bearing by using a composite polymeric-metal structure instead of traditional solid metal or solid polymer bearings. This material parameter change allows the bearing to accommodate larger dimensional variations in the ball stud, housing, and bearing components while maintaining durability and preventing locking issues.
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 solution enables cost and weight savings by using a plastic backing bearing with metal reinforcement, improving durability and allowing for relaxed tolerances without compromising performance, reducing the risk of damage and locking issues.
Implementation Method 1
the reinforcement piece is made of metal, and the reinforcement piece is at least partially embedded within the polymeric piece to resist radial expansion of the polymeric piece
Implementation Method 2
a method of overmolding plastic with metal reinforcement
Data Source
AI summary
The socket assembly includes a housing with an inner bore which extends along a central axis from a generally closed first end to an open second end. A ball portion of a ball stud is received in the inner bore of the housing. The ball stud also has a shank portion which projects out of the inner bore through the open second end. A backing bearing is disposed in the inner bore of the housing and has a curved bearing surface that is in slidable contact with the ball portion of the ball stud. The backing bearing is movable in a radial direction relative to the housing and includes a polymeric piece. The backing bearing further includes a reinforcement piece, which is made of metal, and the reinforcement piece is at least partially embedded within the polymeric piece to resist radial expansion of the polymeric piece.