Segmented Ball Socket Coupling Assembly Retention
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Solution Overview
Problem
Current ball socket coupling assemblies face challenges in retaining a ball stud securely, especially with reduced spherical diameters, which compromise retention surface area, and fail to provide adequate access for drive engagement while maintaining retention during off-axis rotation and increased temperature conditions.
Innovation Solution
A multi-stage assembly process for a ball socket coupling assembly featuring segmented arms, journaling ribs, wedges, and engagement tabs that securely engage a ball stud, allowing off-axis angular displacement and access through the ball socket end, with upper rib portions and wedges providing enhanced retention and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the spherical diameter of the ball head is reduced to address material, weight, and size requirements, then weight and size are improved, but the retention surface area is reduced making it more difficult to retain adequate hold on the ball stud
Solution Approach 1:
The ball socket is segmented into a multi-component structure including a socket body, retention ring, and locking mechanism. This segmentation allows the retention features to be independently optimized and adjusted without changing the ball head size, thereby maintaining retention surface area while using a smaller, lighter ball head.
Solution Approach 2:
The patent introduces axial retention features (retention ring, locking mechanism) along the socket axis to compensate for the reduced radial retention surface area caused by the smaller ball head diameter. This dimensional transition from radial to axial retention solves the contradiction between size reduction and retention strength.
2Strength
If undercuts or lock-edges are applied to the ball head to provide additional resistance from extraction, then retention is improved, but when the system rotates off-axis these undercuts or lock-edges are foreshortened and lose their effectiveness
Solution Approach 1:
The locking mechanism is designed with movable components that can dynamically adjust their engagement position and orientation based on the off-axis rotation angle. This dynamic adaptation maintains effective retention across the full range of motion, preventing the foreshortening problem associated with fixed undercuts.
Solution Approach 2:
The patent employs adjustable retention parameters including the position of the retention ring, the angle of locking surfaces, and the depth of engagement that can be modified to maintain optimal retention forces during off-axis rotation, thereby preserving both retention strength and rotational versatility.
3Ease of operation
If drive access is provided on the ball stud end when installed into the socket, then ease of operation is improved, but existing products fail to couple this access with meeting the desired retention in off-axis angle usage
Solution Approach 1:
The ball socket assembly is designed as a multi-functional system that simultaneously provides drive access through the socket structure while maintaining retention capabilities during off-axis rotation. The integrated design of the retention ring and locking mechanism ensures both functions operate effectively together, resolving the failure of existing single-function designs.
Data Source
AI summary
A coupling assembly is provided that includes a ball socket having a central socket axis, the ball socket includes a lower body portion extending to an upper flange portion, wherein the body portion and flange portion are at least partially segmented by a plurality of longitudinal socket slots to form a plurality of longitudinally extending arms, further included are a plurality of longitudinally extending journaling ribs protruding radially from the body portion, wherein the ribs include an upper rib portion and a lower rib portion, and wherein the upper rib portion has a greater radial width than the lower rib portion, a plurality of wedges extending from the body portion, a plurality of engagement tabs extending from the body portion, each having a tab end portion, and a ball stud engagement cavity centrally formed between the arms for receiving and pivotably securing a ball head of a ball stud therein.