Rib-Reinforced Ball Joint Housing for Equal-Wall Press Forming
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Solution Overview
Problem
The existing ball joint designs require different thicknesses for the bottom and peripheral walls of the metal housing, limiting manufacturing process flexibility and resulting in increased weight and complexity.
Innovation Solution
A ball joint with a metal housing formed by press work, where the bottom and peripheral side walls have equal thicknesses and a boundary portion with rib structures, allowing for equal thicknesses and enhanced deformation strength, and a manufacturing method that includes rib processing and swaging to integrate the ball stud and resin ball seat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bottom wall thickness is increased to withstand axial loads, then the load-bearing capacity is improved, but the weight increases and manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by providing reinforcement ribs only at the bottom wall where axial loads are concentrated, rather than uniformly thickening the entire housing. The ribs are positioned specifically at the load transmission path from the connecting bar to the housing body, creating localized strength enhancement without increasing overall weight.
Solution Approach 2:
The housing bottom wall is segmented into multiple regions by the reinforcement ribs, which divide the load-bearing area into discrete zones. This segmentation allows the structure to distribute axial loads across multiple rib elements rather than requiring a single thick wall, reducing material usage while maintaining strength.
2Strength
If the bottom wall thickness is increased to withstand axial loads, then the load-bearing capacity is improved, but the manufacturing process complexity increases
Solution Approach 1:
The reinforcement ribs are merged with the housing bottom wall as an integrated structure formed in a single press working process. Rather than adding ribs as separate components requiring additional assembly steps, the ribs are formed simultaneously with the housing body, simplifying the manufacturing process while providing the necessary structural reinforcement.
Solution Approach 2:
The patent changes the geometric parameters of the housing bottom wall by introducing rib structures with specific heights, thicknesses, and spacing. These parameter modifications are achieved through adjusted press working conditions, allowing the same manufacturing process to produce both simple and reinforced housing variants without process changes.
3Strength
If different wall thicknesses are used for bottom and peripheral walls, then the load-bearing capacity is improved, but the manufacturing flexibility is reduced
Solution Approach 1:
The housing design with reinforcement ribs serves multiple functions: it provides axial load bearing capacity, maintains manufacturing flexibility through single-process formation, and allows adaptation to different load requirements by varying rib geometry. The same basic housing structure can be produced with different rib configurations to meet various application requirements.
Solution Approach 2:
By changing geometric parameters such as rib height, thickness, and spacing, the housing can be optimized for different load conditions while maintaining the same manufacturing process. This parameter variability provides design flexibility without requiring different manufacturing processes or tooling.
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
This design expands manufacturing process flexibility, contributes to weight reduction, and simplifies the manufacturing process while maintaining structural integrity under axial loads.
Implementation Method 1
The housing (43) is formed into a bottomed cylindrical shape by press work
Implementation Method 2
The bottom wall and the peripheral side wall of the housing have therebetween a boundary portion (52) formed with multiple rib portions (51) which project in a brace shape from outside to inside of the housing
Implementation Method 3
integrating the ball stud with the ball seat attached thereto with the housing by subjecting an opening rim portion of the housing to swaging by bending the opening rim portion inward
Data Source
AI summary
An axial ball joint includes a ball stud including a stud portion and a ball portion; a metal housing configured to rotatably support the ball portion of the ball stud; a resin ball sheet provided in an interposed manner between the ball portion and the housing. The housing is formed in a bottomed cylindrical shape by press work. The housing has a bottom wall and a peripheral side wall which are set respectively to thicknesses substantially equal to each other. The bottom wall and the peripheral side wall of the housing have therebetween a boundary portion formed with multiple rib portions which project in a brace shape from outside to inside of the housing.