Patent Application
20170211613
The present invention relates to a housing including a deformed part forming an edge portion of an opening part of a cylindrical housing body and being plastically deformed to hold a bearing sheet, and a ball joint including the housing.
A ball joint conventionally used for example in a suspension device or a steering device of a vehicle such as an automobile includes: a ball stud corresponding to a ball-side member including a ball part and a stud part as a shaft part projecting from the ball part; a circular cylindrical ball sheet corresponding to a bearing sheet made of synthetic resin, for example, that holds the ball part of the ball stud in a manner that allows rotation of the ball part; a housing in the shape of a circular cylinder with a closed bottom including a housing body with an inner chamber where the ball sheet holding the ball part is received; and a circular cylindrical dust cover attached between the outer peripheral surface of the housing body on one end side and the outer peripheral surface of the stud part.
Such a dust cover may be configured by burying an insert ring into an abutting part (lip part) corresponding to a housing-side end portion as a large-diameter side of the dust cover and fixing the dust cover to an end portion of the housing body by press fitting. This dust cover has a substantially straight shape. Hence, during swinging motion of the ball stud, the dust cover is hard to bend and is pulled to lift the abutting part. This causes risk of reduction in sealing performance or increased probability of deterioration due to insufficient strength to withstand bending.
In response to the aforementioned risk, the configuration has been adopted in which the dust cover is formed into a shape where the dust cover bulges radially at an intermediate position between opposite ends of the dust cover, a fitting groove is formed at the outer peripheral surface of the housing body by cutting, for example, an end portion of the dust cover is fitted in this fitting groove, and then, the dust cover is fixed with an annular clip. In this case, while sealing performance is ensured, cutting process for forming the fitting groove in the housing body is required. This causes increase in production costs in terms of increase in man-hours and increase in processing costs, etc.
The following method has been known that allows the dust cover to be fixed with a clip without requiring cutting process. The ball sheet holding the ball part is press fitted into the inner chamber of the housing. Next, a deformed part at an opening-side end portion of the housing is plastically deformed (deformed by swaging) with a roller or a press to make the deformed part project toward an inner peripheral direction, thereby retaining and fixing the ball sheet and the ball part together in the housing. The deformed part is further made to jut out toward an outer peripheral direction to form a holding part holding an end portion of the dust cover (see Japanese Laid-open Patent Publication No. H07-279943 and Japanese Examined Patent Publication No. H05-1094, for example).
According to the aforementioned housing, however, the deformed part simply having a straight shape is plastically deformed by applying a load on the deformed part. Hence, the load acts further on a part of the housing where the ball sheet is housed. Hence, in some cases, in order to avoid unnecessary deformation, adjustment of the load for the plastic deformation or an additional configuration, etc is required.
The aforementioned problem occurs not only in a ball joint for use in a vehicle and a housing of this ball joint but also in a ball joint used in any place and a housing of this ball joint.
The present invention has been made in view of these circumstances. It is an object of the present invention to provide a housing with a holding part which holds an end portion of a dust cover and which can be formed at a low cost by deforming only a deformed part reliably without requiring additional process, and a ball joint including the housing.
A housing of a ball joint includes a cylindrical housing body including an inner chamber housing a bearing sheet that holds a ball part of a ball-side member in a manner that allows rotation of the ball part, the housing body including an opening part communicating with the inner chamber and being provided on at least one end portion of the housing body, the opening part through which a shaft part projecting from the ball part of the ball-side member is inserted; a receiving part provided on one end side of the housing body; and a deformed part provided adjacent to the receiving part and forming an edge portion of the opening part of the housing body. The deformed part is plastically deformed in response to application of a load acting in a direction along an axis direction of the housing body, thereby holding the bearing sheet, while forming a holding part between the deformed part and the receiving part. The holding part holds an end portion of a dust cover covering the opening part. A sum of an angle of an outer side surface of the deformed part relative to an axis-perpendicular direction of the housing body and an angle of an outer side surface of the receiving part relative to the axis-perpendicular direction is set to be less than 180°.
According to a housing of a ball joint as recited above, the receiving part is provided by shape forming, and the angle of the outer side surface of the receiving part relative to the axis-perpendicular direction of the housing body is set to be less than 90°.
Another example of a ball joint includes a ball-side member including a ball part and a shaft part projecting from the ball part; a cylindrical bearing sheet including a holding surface and an opening provided on at least one end portion of the bearing sheet, the holding surface holding the ball part in a manner that allows rotation of the ball part, the opening being formed in the holding surface and through which the shaft part is inserted; the housing as recited, with the bearing sheet holding the ball part in a manner that allows rotation of the ball part being housed in the inner chamber, the deformed part being plastically deformed in response to application of a load acting in the direction along the axis direction of the housing body, thereby holding the bearing sheet in the inner chamber; and a cylindrical dust cover having one end portion held on an outer side surface of the shaft part of the ball-side member. The dust cover has an opposite end portion held by the holding part formed between the deformed part and the receiving part of the housing resulting from deformation of the deformed part, thereby covering the opening part of the housing.
According to a yet another example of a ball joint, the bearing sheet includes a sheet inflected part that permits deformation of a portion along an outer circumferential surface of the ball part and on the opening side to occur in response to plastic deformation of the deformed part of the housing, and the bearing sheet is formed to be thicker gradually from the sheet inflected part toward the opening side.
According to the housing of a ball joint, the sum of the angle of the outer side surface of the receiving part provided on one end side of the cylindrical housing body and the angle of the outer side surface of the deformed part adjacent to the receiving part relative to the axis-perpendicular direction of the housing body is set to be less than 180°. By doing so, the inflected part is formed at an outer side surface of the housing body between the deformed part and the receiving part. A load to be applied for plastic deformation on the deformed part in the axis direction of the housing body is caused to act intensively on the inflected part, so that the load hardly exerts an impact on the receiving part side. Only the deformed part is deformed reliably and the holding part holding the end portion of the dust cover can be formed at a low cost without requiring additional process.
According to the housing of a ball joint as recited above, the receiving part is provided by shape forming. Thus, in addition to achieving the effect of the housing of a ball joint as recited above, the housing of a ball joint as recited herein achieves manufacture at a low cost, compared to provision by cutting, for example. Further, the angle of the outer side surface of the receiving part relative to the axis-perpendicular direction of the housing body is set to be less than 90°. This makes the receiving part jut out and the end portion of the dust cover can be reliably held by the holding part formed between the receiving part and the deformed part after the plastic deformation.
The ball joint can have the housing as recited above. Thus, the holding part holding the end portion of the dust cover can be formed at a low cost without requiring additional process. Thus, the ball joint achieving stable performance can be provided at a low cost.
According to another ball joint, the bearing sheet is formed to be thicker gradually from the sheet inflected part that permits deformation of a portion along the outer circumferential surface of the ball part and on the opening side to occur in response to plastic deformation of the deformed part of the housing toward the opening side. By doing so, most of a deformation load applied on the deformed part acts on a position where the bearing sheet has a large thickness. Thus, in addition to achieving the effect of the ball joint as recited above, the ball joint as recited herein makes it possible to reliably clamp the bearing sheet between the ball part and the deformed part to fix the bearing sheet stably in the inner chamber.
An example of the present invention is described below in terms of its construction by referring to
Referring to
The ball stud 15 is made of metal, for example. The ball stud 15 has a ball part 21 as a substantially spherical ball head part, and a stud part 22 that is a shaft part like a round shaft projecting from the ball part 21 coaxially with the ball part 21 while extending lengthwise in the vertical direction. A flange part 23 is formed integrally with the stud part 22 on an outer peripheral side of the stud part 22 so as to project toward outer side from an intermediate position of the stud part 22 in its lengthwise direction. The stud part 22 has an outer peripheral surface with a screw groove 24 as a connection part formed on an upper end side of the stud part 22. A nut not shown in the drawings is threadedly engaged with the screw groove 24 to fixedly clamp a target of fixation (not shown in the drawings) between the flange part 23 and the nut, thereby connecting the ball joint 11 to the target of fixation.
For example, the ball sheet 16 is made of synthetic resin. The ball sheet 16 includes a sheet body 27 corresponding to a circular cylindrical body part. The sheet body 27 includes a sliding contact surface 31 corresponding to a holding surface in the shape of a spherical surface that holds the outer circumferential surface of the ball part 21 including an equator X thereof in a manner that allows rotation of the ball part 21. The sheet body 27 further includes an upper opening 32 as an (one) opening communicating with the sliding contact surface 31, and a lower opening 33 as an opposite opening communicating with the sliding contact surface 31. The openings 32 and 33 are located at an upper end and a lower end that are opposite ends of the ball sheet 16 (sheet body 27) in an axis direction A (an axis direction of the ball joint 11) corresponding to a specified direction. In the sheet body 27, the openings 32 and 33 each have an opening area smaller than the diameter dimension of the ball part 21 to prevent the ball part 21 from coming off the ball sheet 16. The sheet body 27 is formed to be thicker gradually from a position corresponding to the equator X of the ball part 21 at a substantially central portion between the opposite ends toward the upper opening 32 side. In this way, a sheet inflected part 34 of the ball sheet 16 (sheet body 27) is formed at the position of the sheet body 27 corresponding to the equator X of the ball part 21. The equator X of the ball part 21 means a position where the diameter dimension of the ball part 21 is at a maximum in an axis direction of the ball stud 15.
The housing 17 shown in
The inner chamber 35 is a part to which the ball sheet 16 holding the ball part 21 is fitted, specifically, a part where the ball part 21 is received. The inner chamber 35 includes a circular bottom surface part 41 extending like a flat surface along an axis-perpendicular direction R and a circular cylindrical peripheral surface part 42 standing from a peripheral edge of the bottom surface part 41.
The bottom surface part 41 tightly contacts a lower end corresponding to an opposite end of the ball sheet 16 in the axis direction A fitted in the inner chamber 35. The bottom surface part 41 and the lower opening 33 of the ball sheet 16 define a grease storage space 44 therebetween that is a lubricant housing part to house grease as a lubricant not shown in the drawings.
The peripheral surface part 42 tightly contacts the outer peripheral surface of the sheet body 27 of the ball sheet 16 fitted in the inner chamber 35 with no space therebetween.
The opening part 36 is opened at the upper end of the inner chamber 35. The opening part 36 has a circular shape with an outer edge defined by the peripheral surface part 42.
The receiving part 38 is located on the upper end side corresponding to the one end side of the housing body 37 and extends continuously in a band-like shape around the entire periphery of the housing body 37. Specifically, the receiving part 38 is located above the sheet inflected part 34 of the ball sheet 16 fitted in the inner chamber 35. The receiving part 38 has an inner peripheral surface as a part holding the ball sheet 16. The receiving part 38 has an outer peripheral surface formed to be gradually inclined toward an inner side corresponding to a central axis side of the housing body 37, in other words, to be reduced in diameter dimension (to shrink in diameter) as the outer peripheral surface extends toward the deformed part 39 (inflected part 40) to be directed toward the upper end of the housing body 37. An angle α of the outer peripheral surface of the receiving part 38 relative to the axis-perpendicular direction R of the housing body 37 is set to be less than 90° (acute angle). This makes the receiving part 38 project (jut out) radially toward an outer side of the housing body 37 from the inflected part 40. Further, the outer peripheral surface of the receiving part 38 at its lower end portion forms a projecting part 45 that projects in an outer radial direction from the outer peripheral surface of the housing body 37. The receiving part 38 is apart formed simultaneously with shape forming (forging) of the housing 17 and is not apart formed, for example, by cutting process after shape forming of the housing 17. In this embodiment, the outer peripheral surface of the receiving part 38 has a flat surface shape entirely inclined to the same angle. Alternatively, the outer peripheral surface of the receiving part 38 may partially be provided with recesses and protrusions or may be formed as a curved surface. Thus, the angle α mentioned herein means an angle of a tangent plane of the outer peripheral surface of the receiving part 38 at the position of the inflected part 40 relative to the axis-perpendicular direction R.
The deformed part 39 forms the entire periphery of an edge portion of the opening part 36 at one end portion of the housing body 37. In response to application of a load acting from top to bottom in the axis direction A of the housing body 37, the deformed part 39 is plastically deformed, specifically, deformed by swaging to project toward an inner side corresponding to the central axis side and to project toward an outer side opposite the inner side. As a result, a pressing part 46 projecting toward an inner side is formed to press the ball sheet 16 in the axis direction A, thereby retaining and fixing the ball sheet 16 in the inner chamber 35. Further, an opposite receiving part 47 projecting toward an outer side is formed to form a fitting groove 48 between the opposite receiving part 47 and the outer peripheral surface of the receiving part 38 (
The inflected part 40 is a changeover part between the angle α of the outer peripheral surface of the receiving part 38 and the angle β of the outer peripheral surface of the deformed part 39 relative to the axis-perpendicular direction R. The inflected part 40 is formed by the outer peripheral surface of the receiving part 38 and the outer peripheral surface of the deformed part 39 into a substantially V-shaped groove part. The inflected part 40 extends continuously over the entire periphery of the housing body 37.
The dust cover 18 is also called a dust seal or a boot. For example, the dust cover 18 is entirely formed of soft rubber or soft synthetic resin, etc. An upper end portion of the dust cover 18 forms an upper lip part 51 as an (one) abutting part fitted to the ball stud 15 while extending over the lower end of the flange part 23 and the outer periphery of the stud part 22. The lower end portion of the dust cover 18 forms a lower lip part 52 as an (opposite) abutting part fitted to the fitting groove 48 formed in the housing body 37 of the housing 17. A bulging part 53 radially bulging is formed between the opposite end portions (between the upper and lower lip parts 51 and 52) of the dust cover 18. The bulging part 53 is to receive a deformation load of the dust cover 18 during swinging motion of the ball stud 15. Thus, the dust cover 18 has a compressed circular cylindrical shape having a larger diameter dimension at the bulging part 53 than its axis dimension. The upper lip part 51 of the dust cover 18 is fixed by fastening the outer periphery of the stud part 22 of the ball stud 15. The lower lip part 52 of the dust cover 18 is held and fixed in the fitting groove 48 with a clip 54 as a fixing member having a substantially circular ring shape to cover the opening part 36 of the housing body 37 of the housing 17, thereby preventing entry of dust through the opening part 36.
A method of manufacturing the ball joint 11 of the aforementioned example is described next by further referring to
First, the shape of the housing 17 is formed. In this state, the receiving part 38, the deformed part 39, and the inflected part 40 of the housing 17 are formed. The outer peripheral surface of the receiving part 38 is inclined to the angle α (<90°) relative to the axis-perpendicular direction R. The outer peripheral surface of the deformed part 39 is inclined to the angle β (≦90°) relative to the axis-perpendicular direction R to extend in a direction substantially parallel to the axis direction A in this embodiment. The sum of the angles α and β of the outer peripheral surfaces of the receiving part 38 and the deformed part 39 respectively is less than 180° (
The ball part 21 of the ball stud 15 is press fitted into the ball sheet 16 having a shape formed separately to be held on the sliding contact surface 31. Instead of forming the ball sheet 16 separately from the ball part 21 and press fitting the ball part 21, the ball sheet 16 may also be configured in a manner such that the ball part 21 is formed as a core and the ball sheet 16 is formed on the outer circumferential surface of the ball part 21 by injection molding, for example.
Next, the ball sheet 16 holding the ball part 21 is press fitted into the inner chamber 35 of the housing body 37 of the housing 17 through the opening part 36 (
Then, a load is applied from above in the axis direction A on the deformed part 39 with a roller or a press so as to act on the entire periphery of the deformed part 39. By doing so, the deformed part 39 is plastically deformed (deformed by swaging). The sum of the angle α of the outer peripheral surface of the receiving part 38 relative to the axis-perpendicular direction R and the angle β of the outer peripheral surface of the deformed part 39 relative to the axis-perpendicular direction R is set to be less than 180°. Thus, at this time, the deformation load acts intensively on the inflected part 40. This basically deforms only the deformed part 39 from the inflected part 40, while the load does not act on the receiving part 38. The deformed part 39 is plastically deformed in such a manner that the thickness of the deformed part 39 extends toward an inner side corresponding to the central axis side of the housing body 37 (housing 17) and toward an outer side opposite to the inner side. This makes the pressing part 46 press an upper end portion, specifically, a portion on the upper opening 32 side of the sheet body 27 of the ball sheet 16 housed in the inner chamber 35 toward the outer circumferential surface side of the ball part 21 below the upper end portion of the sheet body 27 to deform this upper end portion along the outer circumferential surface of the ball part 21. Further, with the sliding contact surface 31 tightly contacting the outer circumferential surface of the ball part 21, the upper end portion of the sheet body 27 of the ball sheet 16 (an edge portion of the upper opening 32) is clamped between the ball part 21 and the pressing part 46. In this state, the ball sheet 16 is held in the inner chamber 35. Further, the fitting groove 48 is formed between the opposite receiving part 47 extending toward an outer side formed of the deformed part 39 as a result of its plastic deformation and the receiving part (
Then, the lower lip part 52 at the lower end portion of the dust cover 18 is fitted in the fitting groove 48. Further, abutting contact is formed between the upper lip part 51 at the upper end portion of the dust cover 18 and a lower portion of the flange part 23 to fit the upper lip part 51 to the outer peripheral surface of the stud part 22. Then, the lower lip part 52 is held and fixed in the fitting groove 48 with the clip 54.
As described above, according to the aforementioned example, the sum of the angle α of the outer peripheral surface of the receiving part 38 provided on the upper end side of the cylindrical housing body 37 and the angle β of the outer peripheral surface of the deformed part 39 adjacent to the receiving part 38 relative to the axis-perpendicular direction R of the housing body 37 is set to be less than 180°. By doing so, the inflected part 40 is formed at the outer peripheral surface of the housing body 37 between the deformed part 39 and the receiving part 38. Thus, a load to be applied for plastic deformation on the deformed part 39 in the axis direction of the housing body 37 is caused to act intensively on the inflected part 40, so that the load hardly exerts an impact on the receiving part 38 side. As a result, only the deformed part 39 is deformed reliably and the fitting groove 48 holding the lower end portion (lower lip part 52) of the dust cover 18 can be formed at a low cost without requiring additional process such as cutting.
Specifically, referring to each of cases shown in
The receiving part 38 is provided by shape forming. This enables manufacture at lower costs, compared to provision by cutting, for example. Further, the angle of the outer peripheral surface of the receiving part 38 relative to the axis-perpendicular direction of the housing body 37 is set to be less than 90°. This makes the receiving part 38 jut out radially toward an outer side. Thus, the lower lip part 52 at the lower end portion of the dust cover 18 can reliably be held in the fitting groove 48 formed between the receiving part 38 and the deformed part 39 after the plastic deformation.
Additionally, the outer peripheral surface of the receiving part 38 at its lower end side forms the projecting part 45 that projects radially toward an outer side of the outer peripheral surface of the housing body 37. This can increase a contact area of the receiving part 38 with the lower lip part 52 of the dust cover 18, so that the lower lip part 52 can be held more stably in the fitting groove 48.
By the provision of the aforementioned housing 17, the fitting groove 48 holding the lower end portion (lower lip part 52) of the dust cover 18 can be formed at a low cost without requiring additional process such as cutting. Thus, the ball joint 11 achieving stable performance can be provided at a low cost. Specifically, the following configuration can be adopted: the lower end portion (lower lip part 52) of the dust cover 18, which includes the bulging part 53 between the opposite ends of the dust cover 18 to receive a deformation load on the dust cover 18 during swinging motion of the ball stud 15, is fixed in the fitting groove 48 with the clip 54. This can prevent lift, for example of the lower lip part 52 of the dust cover 18 to be caused by swinging motion of the ball stud 15. Thus, sealing performance can be ensured and performance deterioration due to entry of dust can be prevented reliably. Further, strength to withstand bending can be ensured to suppress early deterioration.
Additionally, the ball sheet 16 is formed to be thicker gradually from the sheet inflected part 34 that permits deformation of a portion along the outer circumferential surface of the ball part 21 and on the upper opening 32 side to occur in response to plastic deformation of the deformed part 39 of the housing 17 toward the upper opening 32 side. By doing so, most of a deformation load applied on the deformed part 39 acts on a position where the ball sheet 16 has a large thickness (position on an upper end side of the sheet inflected part 34). In this way, the ball sheet 16 can reliably be clamped between the ball part 21 and the deformed part 39 and can stably be fixed in the inner chamber 35.
In the aforementioned example, as in another example shown in
In each of the aforementioned examples, as in yet another example shown in
Additionally, in the aforementioned example, the angle α of the outer peripheral surface of the receiving part 38 relative to the axis-perpendicular direction R may be set at about 90°. Specifically, the receiving part 38 may have a linear circular cylindrical shape having a diameter dimension substantially constant in the axis direction of the housing body 37. Even in this case, working effect similar to that of each of the aforementioned embodiments can still be achieved.
The ball joint 11 according to each of the aforementioned examples is applicable not only as a ball joint for use in a suspension device or a steering device but also as any ball joint for use in a vehicle or as any ball joint for use in an object other than a vehicle.
The present invention can suitably be used in a suspension device or a steering device of a vehicle such as an automobile, for example.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-189809 | Sep 2014 | JP | national |
This is a U.S. national phase application under 35 U.S.C. §371 of International Patent Application No. PCT/JP2015/076319, filed Sep. 16, 2015, and claims benefit of priority to Japanese Patent Application No. 2014-189809, filed Sep. 18, 2014. The entire contents of these applications are hereby incorporated by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/076319 | 9/16/2015 | WO | 00 |
