Patent Description:
The present invention relates generally to ball socket connection systems for lamp assemblies. More particularly, the present invention relates to a multi-stage ball socket assembly for securing a ball stud.

It is common, in automobiles, to use a ball joint assembly consisting of a ball socket and mating male spherical ball to secure and aid in the positioning of the light source in a headlamp or fog lamp assembly. As newer technologies and automotive style initiatives have developed, headlamp connection systems have also had to develop to meet the needs of this evolution. Some changes include the need for dynamic travel after the system has been initially installed. Other changes are the change to headlamp systems, like LED style systems, that require consistency at elevated temperatures, increased off-axis angle usage, and higher system retention forces to offset the increased mass of LED style systems. Another change is the reduction in the ball stud ball head spherical diameter. A smaller ball head diameter reduces the available retention surface area typically utilized with traditional techniques. Various attempts have been made to apply undercuts or lock-edges to the head granting additional resistance from extraction. The undercuts can suffice if the pull force is axial, but when the system is required to rotate off-axis, the lock-edge foreshortens and loses its effectiveness, either restricting the system from off-axis rotation or escaping the associated socket locking geometries. Along with the desire to have improved retention there is a need to couple this with a ball socket that allows assembly into a blind boss mating geometry.

As the design of motor vehicle systems continue to develop, the requirements for improvements with automotive interconnection components like ball sockets also continue to develop. There are many prior designs for sockets including, among others, the devices disclosed in <CIT>, in <CIT>; <CIT>; <CIT>; and <CIT>, although these designs suffer from various shortcomings.

As ball diameters decrease to answer specific requirements like material, weight, and size reduction while being contrasted with higher requirements for off axis travel, temperature, and pull out forces, retaining adequate hold on the ball studs becomes more difficult. As such, there is a need for an improved ball socket assembly that can be utilized for multiple ball diameters, and can utilize the entire system to allow easy insertion with improved retention even at increased off-axis rotation requirements while also providing assembly into a blind boss mating geometry.

In at least some other embodiments, a ball socket assembly is disclosed that includes: a ball socket comprising: a socket base having a plurality of socket legs extending therefrom, wherein the socket legs include ball stud interface surfaces forming a ball cavity for receiving and selectively engaging a ball head of a ball stud; a plurality of slots extending between the plurality of socket legs; a lower abutment wall having a bend line and situated in the socket base; and a flexible securing substrate having a plurality of tangs and positioned under the lower abutment wall and substantially centered about the bend line, wherein the tangs extend outward from the socket base; and a mating boss substrate comprising: a first boss inner passage having a first passage inside diameter; a second boss inner passage having a second passage inside diameter, wherein the first passage inside diameter is greater than the second passage inside diameter; a boss transition wall that extends between the first boss inner passage and the second boss inner passage; and a boss bottom situated under the second boss inner passage.

In at least some further embodiments, a ball socket assembly is disclosed that includes: a ball socket comprising: a socket base having an upper base portion and a lower base portion, and a plurality of socket legs extending from the socket base, wherein the socket legs include ball stud interface surfaces forming a ball head cavity for receiving and selectively engaging a ball head of a ball stud; a lower abutment wall having a central bend line and situated in the socket base; and a flexible securing substrate having a plurality of tangs and positioned under the lower abutment wall; and a mating boss substrate comprising: a first boss inner passage sized and shaped to matingly receive therein the upper base portion of the ball socket; and a second boss inner passage, wherein the second boss inner passage is sized and shaped to matingly receive therein the lower base portion of the ball socket.

It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom.

Embodiments of the invention are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The invention is not limited in application to the details of construction or the arrangement of the components illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways as defined by the appended set of claims.

Referring to <FIG>, an exemplary embodiment of a ball socket assembly <NUM> and a ball stud <NUM> are shown. The ball socket assembly <NUM> includes a ball socket <NUM> configured for engagement with a mating boss substrate <NUM>. The ball stud <NUM> is received by the ball socket <NUM> which then further engages the mating boss substrate <NUM>.

<FIG> represent various views of the ball socket <NUM>. The ball socket <NUM> includes a generally cylindrical socket base <NUM> with a plurality of socket legs <NUM> extending therefrom, a plurality of slots <NUM> situated between the socket legs <NUM>, a lower abutment wall <NUM> extending across a central bend line <NUM>, a flexible securing substrate <NUM> positioned under the lower abutment wall <NUM> and bend line <NUM>, a partially spherical ball head cavity <NUM>, and ball stud interface surfaces <NUM>. The ball stud interface surfaces <NUM> are generally curved to matingly receive and engage a generally spherical ball head <NUM> of the ball stud <NUM>, such that the ball head <NUM> is retained while allowing for axial movement. The socket legs <NUM> can further include socket outer leg engagement surfaces <NUM> that taper downward toward the socket base <NUM>, and wherein an outer diameter <NUM> extends about the ball socket <NUM> between the socket outer leg engagement surfaces <NUM>. The socket base <NUM> further includes an upper base portion <NUM> with an upper base portion diameter <NUM> and a lower base portion <NUM> with a lower base portion diameter <NUM>. In at least some embodiments, the lower abutment wall <NUM> is generally V-shaped extending upwards from the bend line <NUM> and away from the lower base portion <NUM> to form a first abutment surface <NUM> and a second abutment surface <NUM>. Further, in at least some embodiments, the lower abutment wall <NUM> is generally planar as it extends from the bend line <NUM>. In at least some embodiments, the bend line can extend perpendicular to the securing substrate <NUM>. Further, in at least some embodiments, the outer diameter <NUM> is greater than the upper base portion diameter <NUM> and/or the lower base portion diameter <NUM>. Other shapes and configurations of the lower abutment wall <NUM> have been contemplated. The securing substrate <NUM> can utilize various materials, shapes, and configurations. In at least some embodiments, the securing substrate <NUM> is formed of stamped metal. The securing substrate <NUM> further includes protruding tangs <NUM> that in at least some embodiments, extend beyond the lower base portion <NUM> and upper base portion <NUM>.

<FIG> also illustrates an exemplary known ball stud <NUM>, which includes the spherical ball head <NUM> sized and shaped to be received and secured by the ball socket <NUM>. <FIG> and <FIG> show features of the exemplary mating boss substrate <NUM>. These features include a first boss inner passage <NUM> having a first passage inside diameter <NUM>, a second boss inner passage <NUM> having a second passage inside diameter <NUM>, a boss transition wall <NUM> that extends between the first boss inner passage <NUM> and second boss inner passage <NUM>, and boss bottom <NUM>. In at least some embodiments, the first passage inside diameter <NUM> is greater than the second passage inside diameter <NUM>. In addition, the first boss inner passage <NUM> is sized and shaped to receive and compress inward the socket outer leg engagement surfaces <NUM> of the ball socket <NUM>, while the second boss inner passage <NUM> is sized and shaped to matingly receive therein the lower base portion <NUM> of the ball socket <NUM>. The features shown represent one of multiple geometries that could be utilized to aid in the orientation and assembly process. In addition, the mating boss substrate <NUM> can take numerous forms including various shapes, sizes, and materials, and can be included as an integral part of an automotive component/assembly (e.g., automotive headlamp housing) or as a stand-alone component that is securable to an automotive component/assembly. In at least some embodiments, the mating boss substrate <NUM> is formed as part of a lighting assembly, while in other embodiments, the mating boss substrate <NUM> is formed as part of an automobile that the lighting assembly is secured to. For illustrative purposes, the mating boss substrate <NUM> is shown in the form of a cylinder <NUM> that extends from a flange <NUM>, wherein the cylinder <NUM> or flange <NUM> can be part of a lighting assembly or automobile, although the cylinder <NUM> can effectively be recessed/integrally formed so as not to protrude from a surface in whole or in part.

<FIG> is a top view of the ball socket assembly <NUM> with the ball socket <NUM> assembled with the mating boss substrate <NUM> in an exemplary first stage assembly position. <FIG> is a cross-section view of the ball socket assembly taken along lines <NUM>-<NUM> of <FIG>. In this state the ball socket <NUM> is installed into the mating boss substrate <NUM> at a controlled height by utilizing the interaction between the securing substrate <NUM> and boss transition wall <NUM>. Retention of the ball socket <NUM> into the mating boss substrate <NUM> is controlled by the interaction of the securing substrate <NUM> engaging the first boss inner passage <NUM> by means of a controlled level of interference. Center alignment of the ball socket <NUM> relative to the mating boss substrate <NUM> in the first stage assembly position is controlled by the mating interface between the lower base portion diameter <NUM> and the second boss inner passage <NUM>. At this stage, the ball socket <NUM> has been partially installed into the mating boss substrate <NUM> and the ball stud <NUM> has not be introduced.

<FIG> is a side view illustrating the first stage assembly position of the ball socket in the mating boss substrate, and with the ball stud shown prior to installation into the ball socket <NUM>. <FIG> is a side view of the first stage assembly position of the ball socket <NUM> in the mating boss substrate <NUM> with the ball head <NUM> installed in the ball socket <NUM>. <FIG> is perspective view of the ball socket assembly and ball stud of <FIG>. <FIG> is a cross-section view of the ball socket assembly and ball stud of <FIG>.

The interaction between the securing substrate <NUM> and the boss transition wall <NUM> provides a controlled level of resistance to allow the ball stud <NUM> to be pressed into the ball socket <NUM> while maintaining the first stage assembly position of the ball socket assembly <NUM>. In the first stage assembly position, due to the raised (not fully seated) position of the ball socket <NUM>, the socket legs <NUM> are allowed to flex open to receive the ball head <NUM> with a force less than the resistance created by the interaction between the securing substrate <NUM> and the boss transition wall <NUM>. Once the ball stud <NUM> is engaged inside the ball socket <NUM> the ball head <NUM> and the ball head cavity <NUM> will be in position for the second stage of assembly.

<FIG> is a perspective view illustrating an exemplary second stage assembly position of the ball socket assembly <NUM> and ball stud <NUM>. <FIG> is a cross-section view of the ball socket assembly and ball stud of <FIG>. Continued assembly force exerted on ball stud <NUM> after installation inside the ball socket <NUM> as illustrated in <FIG>, overcomes the controlled resistance facilitated by the interference of the securing substrate <NUM> and boss transition wall <NUM>, allowing the ball socket <NUM> to be further inserted into the mating boss substrate <NUM> until it seats at the boss bottom <NUM> inside the mating boss substrate <NUM>. The upward force on the tangs <NUM> combined with the downward force of the bend line <NUM> cause the securing substrate <NUM> to fold up towards the lower abutment wall <NUM> until abutment. At the second stage assembly position the ball socket <NUM> is retained to the mating boss substrate <NUM> by engagement of the tangs <NUM> of the securing substrate <NUM> with the second boss inner passage <NUM>. In at least some embodiments, the degree of engagement between the securing substrate <NUM> and the second boss inner passage <NUM> is controlled by a resultant bend angle <NUM> (see <FIG>) of the securing substrate <NUM> in the second stage assembly position. The bend angle <NUM> of the securing substrate <NUM> is provided at least in part by the interaction of the securing substrate <NUM> with the bend line <NUM> of the lower abutment wall <NUM> and the engagement of the tangs <NUM> with the boss transition wall <NUM>. The resultant bend angle <NUM> is generally equal to a boss angle <NUM> (see <FIG>) of the lower abutment wall <NUM> (see <FIG>). The boss angle <NUM> can vary, and in at least some embodiments, is between about <NUM> degrees and about <NUM> degrees, while in other embodiments, other angles can be utilized. The ball head <NUM> of the ball stud <NUM> is retained inside the ball socket <NUM> at the second stage assembly position by its interaction with the ball stud interface surfaces <NUM>. This interaction is facilitated by the inward movement of the socket outer leg engagement surfaces <NUM> when the socket legs <NUM> are forcible pushed inward by the narrower first boss inner passage <NUM> as increased installation force is applied to the ball stud <NUM>. In this final position, the socket legs <NUM> are fully constrained inside the first boss inner passage <NUM>, which restrains any opening of the ball socket <NUM> when a pull out force is applied to the ball stud <NUM>, thereby providing high levels of retention for a ball head <NUM> with or without an undercut at any allowable axial angle.

<FIG> is a perspective view of the ball stud <NUM> and an exemplary second embodiment of the ball socket assembly <NUM>, which includes ball socket <NUM> and mating boss substrate <NUM>. <FIG> illustrative various views of the ball socket <NUM>. The ball socket <NUM> is substantially similar to ball socket <NUM>, although it further includes a plurality of securing substrate support slots <NUM> (<FIG>) and socket alignment ribs <NUM>. As ball socket <NUM> includes many elements found in ball socket <NUM>, these similar elements have been labelled similarly, with the notion of using a two-hundred series numbering (i.e., <NUM>/<NUM>, <NUM>/<NUM>, <NUM>/<NUM>, etc.), such numbering indicates like elements performing like functions.

<FIG> is a perspective view of the mating boss substrate <NUM>. <FIG> is a cross section view of the mating boss configuration of <FIG>. In at least some embodiments, the mating boss substrate <NUM> includes a first boss inner passage <NUM> having a first passage inside diameter <NUM>, a second boss inner passage <NUM> having a second passage inside diameter <NUM>, a boss transition wall <NUM> that extends between the first boss inner passage <NUM> and second boss inner passage <NUM>, a plurality of securing substrate supports <NUM> extending inward from the second boss inner passage <NUM>, a boss bottom <NUM>, and a plurality of alignment slots <NUM> extending through both the first boss inner passage <NUM> and the second boss inner passage <NUM>. In at least some embodiments, the first passage inside diameter <NUM> is greater than the second passage inside diameter <NUM>.

The illustrated securing substrate supports <NUM> and alignment slots <NUM> represent one of multiple geometries that could be utilized to aid in the orientation and assembly process. In addition, the mating boss substrate <NUM> can take numerous forms including various shapes, sizes, and materials, and can be included as an integral part of an automotive component/assembly (e.g., automotive headlamp housing) or as a stand-alone component that is securable to an automotive component/assembly.

<FIG> is a top view of the ball socket assembly <NUM> with the ball socket <NUM> assembled with the mating boss substrate <NUM> in an exemplary first stage assembly position with the tangs <NUM> resting on the boss transition wall <NUM>. <FIG> is a cross-section side view of the ball socket assembly <NUM>. <FIG> is a side view illustrating the first stage assembly position of the ball socket <NUM> in the mating boss substrate <NUM>, and with the ball stud <NUM> shown prior to installation into the ball socket <NUM>.

<FIG> is a side view of the first stage assembly position of the ball socket <NUM> partially in the mating boss substrate <NUM> and with the ball stud <NUM> installed in the ball socket <NUM>. <FIG> is a top perspective view of the first stage assembly position of the ball socket in the mating boss substrate with the ball stud installed in the ball socket.

<FIG> is a cross-section view of the ball socket assembly <NUM> and ball stud <NUM> of <FIG>. In the first stage assembly position, the ball socket <NUM> is installed into the mating boss substrate <NUM> at a controlled height by utilizing the interaction between the securing substrate <NUM> and the boss transition wall <NUM>. Retention of the ball socket <NUM> in the mating boss substrate <NUM> is controlled by the interaction of the tangs <NUM> (i.e., their outside edges) of the securing substrate <NUM> engaging the boss transition wall <NUM> by a controlled level of interference. Center alignment of the ball socket <NUM> relative to the mating boss substrate <NUM> in the first stage assembly position is controlled by the interaction between the socket base <NUM> and the second boss inner passage <NUM>, as well as the interaction between the socket alignment ribs <NUM> and the alignment slots <NUM>.

The interaction between the securing substrate <NUM> and boss transition wall <NUM> provides a controlled level of resistance to allow the ball stud <NUM> to be pressed into the ball socket <NUM> while maintaining the first stage assembly position. At the first stage assembly position the socket legs <NUM> are allowed to flex open to receive the ball head <NUM> with a force less than the resistance created by the interaction between the securing substrate <NUM> and the boss transition wall <NUM>. Once the ball stud <NUM> is engaged inside the ball socket <NUM>, the ball head <NUM> and the ball head cavity <NUM> will be in contact for the stage two assembly process.

Continued assembly force exerted on ball stud <NUM> after installation inside the ball socket <NUM> overcomes the controlled resistance facilitated by the interference of the securing substrate <NUM> and boss transition wall <NUM> allowing the ball socket <NUM> to be inserted until it seats with the boss bottom <NUM> inside the mating boss substrate <NUM>, as seen in <FIG>, which provides a perspective view illustrating an exemplary second stage assembly position of the ball socket assembly <NUM> and the ball stud <NUM>. <FIG> is a cross-section view of the ball socket assembly <NUM> and ball stud <NUM> of <FIG>.

At the second stage assembly position the ball socket <NUM> is retained to the mating boss substrate <NUM> by the means of engagement between the outside edges of the securing substrate <NUM> and the second boss inner passage <NUM>. The degree of engagement between the securing substrate <NUM> and the second boss inner passage <NUM> is controlled at least in part by the bend angle <NUM> of the securing substrate <NUM> in the second stage assembly position. The bend angle <NUM> is controlled at least in part by the securing substrate's interaction with the socket bend line <NUM>, the lower abutment wall <NUM>, a boss angle <NUM> (see <FIG>) of the lower abutment wall <NUM> (see <FIG>), and the boss transition wall <NUM>. The resultant bend angle <NUM> is generally equal to the boss angle <NUM> of the lower abutment wall <NUM>). The boss angle <NUM> can vary, and in at least some embodiments, is between about <NUM> degrees and about <NUM> degrees, while in other embodiments, other angles can be utilized.

When a pull out force is applied to the ball socket <NUM> the securing substrate supports <NUM> in the mating boss substrate <NUM> serve to interact with the securing substrate <NUM> by preventing the securing substrate <NUM> from bending downward which would release the tension of the tangs <NUM> against the walls of the second boss inner passage <NUM>. The ball head <NUM> of the ball stud <NUM> is retained inside the ball socket <NUM> at the second stage assembly position by its interaction with the ball stud interface surfaces <NUM>. This interaction is facilitated by the inward movement of the socket legs <NUM> which occurs when the socket outer leg engagement surfaces <NUM> interact with the first boss inner passage <NUM>. When completely installed, the socket legs <NUM> are fully constrained inside the first boss inner passage <NUM> which restrains any opening of the ball socket <NUM> when a pull out force is applied to the ball stud <NUM> providing high levels of retention for a ball head <NUM> with or without an undercut at any allowable axial angle.

Claim 1:
A ball socket assembly comprising:
a ball socket comprising:
a socket base having a plurality of socket legs extending therefrom, wherein the socket legs include ball stud interface surfaces forming a ball cavity for receiving and selectively engaging a ball head of a ball stud;
a plurality of slots extending between the plurality of socket legs;
a lower abutment wall having a bend line and situated in the socket base; and
a flexible securing substrate having a plurality of tangs and positioned under the lower abutment wall and substantially centered about the bend line, wherein the tangs extend outward from the socket base; and
a mating boss substrate comprising:
a first boss inner passage having a first passage inside diameter;
a second boss inner passage having a second passage inside diameter, wherein the first passage inside diameter is greater than the second passage inside diameter;
a boss transition wall that extends between the first boss inner passage and the second boss inner passage; and
a boss bottom situated under the second boss inner passage.