Stabilizer Link Dust Cover Sealing Injection Molding
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Solution Overview
Problem
Conventional methods for producing stabilizer links using aluminum or resin materials face issues such as high production costs due to the need for heat-resistant materials and complex processes, and existing resin-based methods do not adequately address cost reduction or sealing characteristics during injection molding.
Innovation Solution
A production method involving injection molding of a subassembly comprising a stud ball, ball seat, and dust cover, where the subassembly is inserted into a die with a radial direction surface pressing portion to improve sealing characteristics and prevent resin leakage, using a resin with a lower melting point to reduce costs and simplify the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum material is used for housing and support bar to reduce weight, then weight reduction is achieved, but production cost increases due to need for heat-resistant materials and complex processes
Solution Approach 1:
The invention changes the material parameter from aluminum to resin, which has a lower melting point and can be processed at lower temperatures. This allows the use of standard injection molding processes without requiring heat-resistant materials or complex thermal management systems, thereby reducing production cost while maintaining weight reduction benefits
Solution Approach 2:
The invention uses resin as a composite material for the housing and support bar, replacing metal materials. The resin material provides sufficient mechanical properties for the application while enabling simpler, more cost-effective manufacturing processes through standard injection molding techniques
2Ease of manufacture
If resin material is used for housing and support bar to reduce cost, then production cost is reduced, but sealing characteristics deteriorate due to resin leakage during injection molding
Solution Approach 1:
The invention segments the assembly process by first creating a subassembly with the dust cover and ball seat, then injecting resin around this pre-assembled unit. This segmentation allows the dust cover to be properly positioned and sealed before the resin injection process, preventing leakage while maintaining cost benefits of resin material
Solution Approach 2:
The invention performs preliminary assembly of the dust cover and ball seat before the resin injection process. By pre-positioning these components and ensuring proper sealing interfaces are established beforehand, the system prevents resin leakage during injection while maintaining the cost advantages of using resin materials
3Strength
If thermal caulking process is used to fix ball seat to housing, then joining strength is improved, but manufacturing complexity increases and production time is extended
Solution Approach 1:
The invention merges the ball seat fixation process with the housing injection molding process. The ball seat is fixed to the housing through the resin injection itself, which simultaneously provides both the structural housing and the anchoring mechanism for the ball seat, eliminating the need for separate thermal caulking operations
Solution Approach 2:
The resin material serves multiple functions: it forms the housing structure, provides structural support for the support bar, and simultaneously acts as the bonding agent to fix the ball seat to the housing. This multi-functionality eliminates the need for separate joining processes like thermal caulking, reducing manufacturing complexity
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 method effectively prevents resin leakage and reduces production costs by improving sealing characteristics and eliminating the need for thermal caulking, while allowing for the use of less expensive materials and simplifying the production process.
Implementation Method 1
an outer peripheral side radial direction surface of the fixing portion is pressed toward the flange portion by a radial direction surface pressing portion of the die
Implementation Method 2
injection molding is performed by injecting a resin into the cavity
Data Source
AI summary
The inner peripheral side radial direction surface of the fixing portion of the dust cover is abutted to the outer peripheral side radial direction surface of the flange portion of the ball seat, and the end portion of the fixing portion is abutted to the side surface of the outer peripheral side of the ball seat. The outer peripheral side radial direction surface of the fixing portion is pressed toward the flange portion by the radial direction surface pressing portion of the die member, and the fixing portion of the dust cover is held by the radial direction surface pressing portion of the die member and the flange portion. The pressing by the radial direction surface pressing portion is appropriately performed to withstand an injection molding pressure of the resin injection.