CROSS AXIS BALL AND SOCKET JOINT WITH SEALING RING FOR CROSS AXIS SLEEVE ENDS

FIELD OF THE INVENTION

[0001] The present invention relates to cross axis joints in general and more particularly to cross axis ball and socket joint constructions having a ball sleeve with a through hole and a central ball with pivot pin ends (sleeve ends) having a sealing area on the outer surface for connection with a bellows element (sealing boot).

BACKGROUND OF THE INVENTION

[0002] Cross axis joints are known that include a central ball joining two pivot pins

(stud ends). Such ball-and-socket joints make possible a controlled movement of two adjacent components in relation to one another. The central ball joint is mounted in a bearing shell which is supported within a housing. The ball and pivot pin structure is hollow providing a

ball sleeve for receiving a bolt.

[0003] A cross axis joint is a ball-joint especially designed to carry loads in a radial

direction and transfer such loads to a mating part by clamping force and friction. Typically, a two-sided device (connection part frame with two flanges) is touching the respective surfaces of the inner sleeve. The devices (flanges) have a through hole and during the assembly process a bolt will be put through the device and the inner diameter or through hole of the cross axis joint. After that the bolt will be tightened up, so that the contact friction (between end face and connection piece) will keep the joint from moving. Typically the cross axis joint is used as a damper joint (housing is pressed in into the damper) or as a pivot joint as replacement for a bushing at the control arm subframe connections at the front suspension and in addition as a knuckle joint in the rear suspension. Washers and built up inner sleeves are known to be provided between the connection part and the sleeve end face, but they show the disadvantage that either the washers are pressed in, into the inner diameter and reduce therefore the crush load, or increase the outer diameter or the built up ones also reduce the crush load for a certain diameter. Currently it is difficult to seal cross-axis joints, this is primarily due to lack of sealing areas and "protection" of the mating part surface. Common current designs have ferrulls (washers) that are pressed into the inner bore of the sleeve. This requires the bore to be oversized (typically 2mm larger than the bolt diameter) which determines the cross-axis opening requirement and sleeve thickness. There may be a quality concern that the washers could fall off during delivery to the customer.

[0004] US patent application publication 2004146338 (also DE10202022) discloses ball-and-socket joints including a cross axis type. One component is connected via a bolt accommodated within the hole of the ball sleeve to another component that is fastened on the outside of the joint housing. The bearing shell is fixed by two closing rings in the axial

direction of the longitudinal axis of the pivot pin. For fixing the bearing shell, these closing rings have a cylindrical outer contour and an inner side to the outer contour of the bearing shell. The sealing boot connects to the housing at the outer contour of the closing ring. The outer surface of each pivot pin end has a sealing area with a contour for receiving a bellows element.

[0005] DE 10362009 discloses a ball-and-socket joint for automobiles and aircraft undercarriages with a housing having a main section and ring parts. The housing has an internal section or ball sleeve with a bearing surface and a bearing shell in the housing main section. The outer surface of each pivot pin end of the ball sleeve has a sealing area with a contour for receiving a bellows element.

[0006] The shaping of an outer surface of each pivot pin end of the ball sleeve with a sealing area contour for receiving a bellows element has disadvantages. The shaping or framing of the pivot ends lowers the material properties and lowers the ability to withstand clamping forces. The bolt is otherwise sized so as to provide a clamping force (e.g. to generate friction between the bolt and surface and a part clamped to the ball sleeve) that is enough such that radial loads can be withstood without slipping. The ball sleeve must withstand clamping forces of the bolt without yielding or crushing. As such the amount of surface area of the ball

sleeve end face needed in contact with the clamped part needs to become larger. As such, washers have been used to increase this area for clamping. Washers can be used at an end face of the ball sleeve and these may extend to the interior of the sleeve. These then limit the bolt size that can fit through the sleeve opening or the construction must be oversized.

SUMMARY OF THE INVENTION

[0007] It is an object of the invention to provide an improved ball and socket joint, particularly a cross axis joint that is free of the problems noted above and which is simple in design, rugged in construction and is economical to manufacture.

[0008] According to the invention, a ball joint is provided comprising a housing, a

bearing shell in the housing and a ball sleeve. The ball sleeve includes a ball portion with a bearing surface cooperating with the bearing shell and a first pivot pin and a second pivot pin extending from the ball portion in an axial direction. The ball sleeve has an inner surface defining a through hole for receipt of a connection bolt. The first pivot pin has a first end with a first outer surface and a first annular end face. The second pivot pin has a second end with a second outer surface and a second annular end face. A first sealing ring is provided having a first axially extending portion extending along the first outer surface and having a sealing area outer surface defining a first bellows seal seat and a radially extending portion extending along the first end face. A second sealing ring is provided having a second axially extending portion extending along the second outer surface and having a sealing area outer surface defining a second bellows seal seat and a radially extending portion extending along the second end face. A first bellows seal is connected to the housing at one end and connected to the first bellows seal seat at a first bellows other end. A second bellows seal is connected to the housing at one end and connected to the second bellows seal seat at a second bellows other end.

[0009] A retaining means may be provided associated with each of the first sealing ring

and the second sealing ring for retaining the first axially extending portion relative to the first

outer surface and retaining the second axially extending portion relative to the second outer

surface.

[0010] The retaining means may comprise a bent end of each axially extending portion

having an edge engaged in the pivot pin outer surface. The retaining means may also comprise a radially protruding potion at an end of each the axially extending portion and a recess in each the outer surface to receive an associated protruding potion. Each outer surface of the axially extending portion may include the protruding potion to define the bellows seal seat.

[0011] Each the radially extending portion extending along the first end face may advantageously include a facing portion extending from the axially extending portion toward the through hole and facing the end face and a folded over portion extending from the facing portion radially away from the through hole to define a connected part contact surface. Each radially extending portion extending along the first end face may advantageously include a facing portion extending from the axially extending portion toward the through hole and facing the end face and a folded over portion extending from the facing portion radially away from the through hole to define a connected part contact surface.

[0012] The retaining means may comprise an interference fit between the axially

extending portion and the pivot pin outer surface. This may be implemented by roughening a contact surface and/or by dimensioning the parts for interference fitting. Where the retaining means includes such a roughened surface between the axially extending portion and the pivot pin outer surface and/or the end face, good clamping/retention is achieved.

[0013] The invention provides improved sealing performance including an increase

sealing area/protection as well as a possible use of "thick coatings (Everlube, Geomet). The sealing area is over one surface, not multiple surfaces. The ball sleeve can be straight or any easily produced shape so as to remove some of the complexity from the formation of the ball sleeve in order to compaensate for the additional costs of the ring. The invention allows for

the potential use of a ball sleeve raw part with minimum machining versus typical screw machine sleeve.

[0014] The sealing rings have the function of a washer (increased bearing area) at the interface of the pivot pin end face (sleeve end face) and the connected part. This sealing ring

functioning as a washer is fixed onto assembly and it is not possible for it to fall off (the sealing boot or bellows seal locks it onto part).

[0015] A thick metal piece design may also act as a ferrull but without increasing the bore size and without the associated manufacturing and quality problems with the "interior" press-in (falling off, presence check).

[0016] The invention also presents the advantage that there is a potential for reduced coating costs of coating the entire stud (pivot pin) versus only covering the sealing rings or the cap part (caps are symmetrical so only one piece is coming into a production area). Further, it is possible to roughen an inner axially extending surface (and also the radially extending surface) of the sealing ring surface, thereby increasing the friction of the clamped connection (whereby it is possible to downsize the bolt and the joint). Such a cross axis or X-axis joint according to the invention is more robust than prior joints and can pass key-life testing based on the ring providing an amount of sealing surface for opportunity to add pre-seal'lips.

[0017] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which

preferred embodiments of the invention are illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In the drawings:

[0019] Figure 1 is a schematic perspective view showing the ball joint according to the invention as well as the environment of the ball joint according to the invention;

[0020] Figure 2 is a cross-sectional view of the ball joint according to the invention including sleeve sealing rings;

[0021] Figure 3 is a sectional view showing a first embodiment of a ball sleeve sealing ring according to the invention;

[0022] Figure 4 is a sectional view showing a second embodiment of a ball sleeve

sealing ring according to the invention;

[0023] Figure 5 is a top view showing a third embodiment of a ball sleeve sealing ring

according to the invention;

[0024] Figure 6 is a sectional view showing a fourth embodiment of a ball sleeve sealing ring according to the invention; and

[0025] Figure 7 is a sectional view showing a fifth embodiment of a ball sleeve sealing

ring according to the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Referring to the drawings in particular, the invention comprises a ball joint 10, particularly a cross axis joint designed to carry loads in a radial direction and to transfer the load between two mating parts. In the example shown in Figure 1 , the ball joint 10 has a main housing part 28 (Figure 2) connected to an arm 12. Another part 14 is in the form of a two sided device, namely with a first flange 20 and second flange 22. The flanges have holes 24 and 26 to receive a bolt 16 with a nut 18. The bolt 16 passes through a through opening 50 of the ball joint 10.

[0027] Figure 2 shows a first embodiment of the ball joint 10 according to the invention. A metallic housing 30 is provided supporting a bearing shell 30 in an inner space. The bearing shell 30 is held in place by a lower intermediate part 32 and lower housing ring 36 at one end and by an upper intermediate part 34 and upper housing ring 38. The rings 36 and

38 are held in position by a deformation of the ends of the material of the main housing part 28, to lock the rings 36 and 38 in position. Within the bearing shell 30 a ball sleeve 40 is provided,

particularly with a ball sleeve bearing surface 46 in contact with the bearing shell 30. The ball sleeve 40 has the inner through opening 50 and has first and second (shown as upper and lower) pivot pins (also referred to as studs) with outer sleeve surfaces 42 and 44. The ball sleeve 40 also has a first end face 41 and a second end face 43. A sealing ring 60 is provided at

each end of the ball sleeve 40. Each sealing ring 60 includes a radially extending part 62 extending along the end face (43 or 41 respectively) and an axially extending part 64 extending along the outer sleeve surface (42 or 44 respectively). Each sealing ring 60 provides a friction clamping surface 65 of the radially extending part 62, that will come in contact with the connection part (20 or 22). Each axially extending part 64 includes an inner surface 66 in contact with the sleeve outer surface (42 or 44). Each axially extending part 64 has an outer surface 66 which defines a sealing bellows seat. As shown, the housing rings 38 and 36 each define a sealing bellows seat to receive an end of a sealing bellows 54 or 52. Sealing bellows 52 has an end 56 seated in the seat 68 and held by clamping element 57. Sealing bellows 54

has an end 58 seated in the seat 68 of the respective sealing ring 60 and held by clamping

element 59.

[0028] Figure 3 shows an enlarged cut away sectional view of the sealing ring 60, according to the first embodiment of the invention. The sealing ring 60 is formed of a thin annular metal piece with a first bend 73 that forms the radially extending parts 62 with a fold

over region above and below the bend 73. This provides the surface 65 as a contact surface with a larger surface area than the end face 43 (or 41) of the ball sleeve 40. As can be seen a Figure 3 the axially extending part 64 provides the seat 68. The axially extending part 64 also has the upper that part 73 with an edge 70 that extends into a recess 72 at the outer sleeve

surface 44 (or outer sleeve surface 42).

[0029] Figure 4 shows a second embodiment that is a variation of the embodiment of

Figure 3. According to the second embodiment of the sealing ring 60' of Figure 4, the radially extending part 62 and the axially extending part 64 are the same as shown in Figure 3, except

the axially extending part 64 has abend 71 providing an edge portion 70' that engages the outer sleeve surface 44 (or outer sleeve surface 42) without the need for a groove on the outer sleeve surface 44 (or outer sleeve surface 42). The edge portion 70' engages the outer sleeve surface 44 (or outer sleeve surface 42) to hold the sealing ring 16 in place.

[0030] A third embodiment according to invention is provided with the structure as

shown in Figures 3 or 4 (or one of the other embodiments) but with a roughened inner surface at extending part 62 and/or the axially extending part 64. Additionally, or as an alternative, the facing surfaces (side 42, 44 and/or bottom 43, 41) of ball sleeve 40 may be roughened. Figure 5 shows a sealing ring 60" with an axially extending part 64 with an inner surface 66 in contact with the outer surface 44. The radially extending part 62 and the axially extending part 64 do

not need to have a bent part 73, 71 but this may also be provided otherwise as shown in Figures 3 and 4. The contact and the connection of axially extending part 64 to outer surface 44 is in the form of an interference fit. Further, good connection properties may be obtained in this regard wherein the surface 66 (or the outer surface of 44 or 42) are roughened to increase friction. This interference fit and/or roughened surface fit provides increased friction that can be used to hold the sealing ring 60" in place, particularly also with the force applied by the bellows seal ends 56 and 58 (sealing boot ends) in an assembled position.

[0031] Figure 6 shows a cross-sectional view of a fourth embodied according to the

invention. According to the fourth embodiment, a sealing ring 90 is provided in place of the sealing ring 60 shown in Figure 2. The sealing ring 90 provides a sealing seat 98 for receiving the end 56 (or 58) of the bellows seal 52 (or 54). However the sealing ring 90 is provided as a thick piece of metal with machined surfaces with a surface 92 at the end face 43 (or 41) and a contact surface 91 that will be in contact with the connection part (20 or 22). The machined or

otherwise provided surfaces also include a radially protruding part 93 with one side protruding into a groove 72 at the outer sleeve surface 44 (or 42) and another side protruding to form the seat 98. The sealing ring 90 may be pressed onto the end of the sleeve 40 allowing the radially protruding part 93 to engage the grooved 72 to lock the sealing ring 90 in place.

[0032] Figure 7 shows in a cross sectional view a fifth embodiment according to the invention. A thick metal blank is provided which is folded at radially extending parts 96 and 97 to form the annular sealing ring 95. This provides an inner surface 102 in contact with the end face 43 (or end face 41) and an outer surface 101 that will be in contact with the connection part (20 or 22). Further, an axially extending part 98 extends toward the ball surface 46 from the radially extending part 97. The axially extending part 98 extends along the outer surface 44 to a bent region 99. The bent region 99 provides an edge 104 that is engaged in a groove 72 on the outer surface 44 (or outer surface 42). As such, the sealing ring 95 is retained relative to the ball sleeve 40. As with the other embodiments, the sealing ring 95 provides a bellows seal seat 98.

[0033] While specific embodiments of the invention have been shown and described in

detail to illustrate the application of the principles of the invention, it will be understood that the invention maybe embodied otherwise without departing from such principles.