Stabilizer Link Ball Seat Fixing via Injection Molding
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Solution Overview
Problem
The existing methods for fixing a ball seat in a stabilizer link using thermal caulking or ultrasonic caulking with reinforced resin often result in breakage of reinforcing fibers, making it difficult to achieve the desired pull-out strength, and may compromise the bearing function of the ball seat.
Innovation Solution
A production method involving injection molding of reinforced resin into a cavity formed between the ball seat and housing, with specific fit shapes and projections to mechanically engage the fixing portion with the ball seat, allowing for enhanced pull-out strength without chemical combination of resins, and preventing removal of the ball seat from the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal caulking or ultrasonic caulking is used to fix the ball seat with reinforced resin, then the pull-out strength is improved, but the reinforcing fibers break and the bearing function deteriorates
Solution Approach 1:
The ball seat is divided into two distinct parts: a main body made of resin without reinforcing agents that contacts the ball portion, and a fixing portion made of reinforced resin that provides pull-out strength. This segmentation allows each part to fulfill its specific function without compromise - the main body maintains bearing function while the fixing portion provides anchoring strength.
Solution Approach 2:
Different regions of the ball seat have different material properties. The main body uses pure resin for low friction and good bearing characteristics, while the fixing portion uses reinforced resin for high strength. This local differentiation of material quality resolves the contradiction between bearing function and pull-out strength.
2Reliability
If polyoxymethylene without reinforcing agent is used for the ball seat, then the bearing function is maintained, but the pull-out strength is insufficient
Solution Approach 1:
The ball seat is divided into two distinct parts: a main body made of resin without reinforcing agents that contacts the ball portion, and a fixing portion made of reinforced resin that provides pull-out strength. This segmentation allows each part to fulfill its specific function without compromise - the main body maintains bearing function while the fixing portion provides anchoring strength.
Solution Approach 2:
The ball seat uses a composite structure combining pure resin and reinforced resin in different regions. This composite approach allows the system to exhibit both the low-friction bearing characteristics of pure resin and the high-strength anchoring properties of reinforced resin, resolving the contradiction between bearing function and pull-out strength.
3Strength
If a hybrid type ball seat with two-color molding is used, then both pull-out strength and bearing function are realized, but it is difficult to control the reinforcing agent during thermal or ultrasonic caulking
Solution Approach 1:
The ball seat is divided into two distinct parts: a main body made of resin without reinforcing agents that contacts the ball portion, and a fixing portion made of reinforced resin that provides pull-out strength. This segmentation allows each part to fulfill its specific function without compromise - the main body maintains bearing function while the fixing portion provides anchoring strength.
Solution Approach 2:
The invention replaces thermal caulking or ultrasonic caulking processes with a mechanical injection molding process. The reinforced resin is injected into a mold cavity in liquid form, then solidifies to form the fixing portion with integrated fit shapes. This substitution eliminates the reinforcing agent breakage problem associated with thermal and ultrasonic processes while maintaining manufacturing efficiency.
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 method ensures the desired pull-out strength is achieved while maintaining the bearing function of the ball seat, with improved sealing characteristics and reduced risk of breakage, allowing for a wider selection of resin materials and enhanced durability.
Implementation Method 1
an injection molding step in which injection molding is performed such that a reinforced resin is injected into the cavity and the space, and a fixing portion of the ball seat is thereby formed
Data Source
Figure 1~3B
Figure 3~4
Figure 5~6
AI summary
A stabilizer link and a production method therefor, which can obtain desired pull-out strength even when a reinforced resin is used for a fixing portion of a ball seat, are provided. In the formation of the subassembly 100A, the space S is formed between the bottom portion side of the side surface portion of the main body portion 201 of the ball seat 200 and the bottom portion side of the inner surface of the housing 300. The die 600 is provided to the outer surface of the bottom portion side of the housing 300 in the subassembly 100A, and the cavity C is thereby formed. Injection molding is performed such that the reinforced resin R is injected into the cavity C and the space S. The fixing portion 202 shown in Fig. 3 is formed at the bottom portion side of the side surface portion of the main body portion 201 by the injection molding. In this case, the fixing protrusion stripe portion 231, which is fitted to the fixing groove portion 221 of the main body portion201, is formed at the fixing portion 202. The projection portion 232 projecting from the hole portion 320 of the housing to an external portion is formed at the bottom portion of the fixing portion 202, and the projection portion 232 is formed to have the shape engaging with the outer surface of the bottom portion of the housing 300.