Stabilizer Link Caulking with Tapered Slope for Stress Reduction
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Solution Overview
Problem
The existing stabilizer link caulking methods, such as the heat caulking and housing caulking methods, face issues with stress concentration, unstable torque characteristics, and limited accuracy in centering due to direct load application and resin material limitations, which affect the stud releasing load and stability of the ball seat and ball stud connection.
Innovation Solution
A production method for stabilizer links that includes a ball stud, ball seat, and ring member with specific taper and slope portions, where the caulking portion is molded to support the load through a ring member, reducing stress concentration and improving centering accuracy by using a slope taper shape and metal housing for enhanced machining precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat caulking method is used to fix the ball seat to the housing, then the ball seat can be secured, but the thermal caulking portion is exposed to the outside and breaks easily when adhering strong acid or contacting foreign substances
Solution Approach 1:
The patent introduces a resin layer as an intermediary protective coating on the thermal caulking portion. This resin layer acts as a barrier between the caulking portion and harmful external factors (acid and foreign substances), preventing direct contact and reducing the risk of breakage while maintaining the securing function of the caulking portion.
2Force
If the housing caulking method is used to fix the ball seat, then the stud releasing load can be improved, but the load directly acts to the opening side of the ball seat causing excessive pressing and unstable torque characteristics
Solution Approach 1:
The patent introduces a slope portion with a specific inclined surface on the inner peripheral end surface of the ball seat. This creates a localized load distribution path that redirects the caulking load away from the opening side, preventing excessive pressing while maintaining adequate securing force. The inclined surface provides a gradual transition that stabilizes the ball stud positioning and improves torque characteristics.
3Force
If a step portion with U-shaped cross section is used to support the caulking load, then the load can be distributed, but stress concentration occurs at the bending lines formed by caulking
Solution Approach 1:
The patent replaces the U-shaped cross-section step portion with a slope portion featuring an inclined surface. This curved/angled geometry eliminates sharp corners and bending lines where stress concentration would occur. The gradual inclination distributes stress more uniformly across the load-bearing surface, reducing peak stresses while maintaining effective load support.
4Device complexity
If the inner peripheral end surface of the stopper base portion is fixed by a step portion, then the structure is simple, but the accuracy of centering of the ring member is limited
Solution Approach 1:
The patent introduces a slope portion with a specifically designed inclined surface on the inner peripheral end surface of the ball seat. This localized geometric feature provides a precise reference surface for centering the ring member during assembly. The inclined surface creates a self-aligning effect that improves centering accuracy without significantly increasing overall structural 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
This method reduces stress concentration, improves the stud releasing load, and enhances the accuracy of centering, resulting in stable torque characteristics and increased resistance to rotating forces, thereby improving the overall performance of the stabilizer link.
Implementation Method 1
Thermal caulking portions 42 are formed at a bottom portion of the ball seat 40 by a thermal caulking method. Specifically, the thermal caulking portion 42 is a resin portion formed by heating and transforming a pin portion of the ball seat 40 using a heat calking apparatus.
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
A stabilizer link and a production method therefor in which there is less concentration of stress, the stud releasing load is improved, and the accuracy of centering of the ring member is improved. A second subassembly is formed by inserting a ball seat of a first subassembly into a ball seat receiving portion of a housing and by arranging a ring member at an opening side of the ball seat. A stopper base portion is abutted to an opening end surface of the ball seat. An outer peripheral end portion taper surface has a taper shape in which a diameter is increased toward an opening side in an axial direction, in a stopper base portion and it is abutted to a slope portion for a stopper base of the housing. An opening side of the ball seat is pressed through the ring member by caulking inwardly a caulking portion.