Method and apparatus for making a ball and socket joint and joint made by same

Abstract

A molding-in-place technique for joint assemblies, such as a ball joint. The technique is particularly well suited for molding “in-place” a linkage structure about a joint structure. The technique uses a molding assembly having a plurality of centering and sealing structures for sealingly centering the linkage structure about the joint structure. A desired mold material is injected between the linkage structure and the joint structure “in-place” to provide a self-toleranced, self-retained, molded-in-place joint assembly.

1 - 34 . (canceled)  
   
   
       35 . A joint system, comprising: 
 a joint support structure;    a studded joint member disposed within the joint support structure; and    a desired material molded-in-place about the studded joint member and internally retained within the joint support structure, wherein the studded joint member is movable and self-toleranced within the desired material.    
   
   
       36 . The joint system of  claim 35 , wherein the studded joint member comprises a ball-shaped head.  
   
   
       37 . The joint system of  claim 36 , wherein the ball-shaped head is self-centered within the joint support structure.  
   
   
       38 . The joint system of  claim 37 , wherein the desired material comprises a plastic.  
   
   
       39 . The joint system of  claim 37 , wherein the joint support structure comprises an internal socket for the ball-shaped head.  
   
   
       40 . The joint system of  claim 37 , wherein desired material molded-in-place about the studded joint member forms an inner bearing surface about the ball-shaped head.  
   
   
       41 . The joint system of  claim 40 , wherein the inner bearing surface comprises thermodynamically enhanced characteristics provided by a temperature differential between the studded joint member and the joint support structure during in-place-molding of the desired material.  
   
   
       42 . The joint system of  claim 41 , wherein the thermodynamically enhanced characteristics comprise a desired material contraction about the ball-shaped head.  
   
   
       43 . A mold system for a ball joint assembly, comprising: 
 a molding assembly configured to self-tolerance and mold-in-place the ball joint assembly, comprising: 
 a stud receptacle for a studded joint member;  
 a first centering structure for the studded joint member;  
 a second centering structure for a support structure disposed about the studded joint member; and  
 a mold injection nozzle for injecting the desired mold material.  
   
   
   
       44 . The mold system of  claim 43 , comprising a thermodynamic differentiator configured to provide a temperature difference between the studded joint member and the support structure.  
   
   
       45 . The mold system of  claim 44 , wherein the thermodynamic differentiator comprises a heater for the studded joint member.  
   
   
       46 . The mold system of  claim 43 , wherein the first centering structure comprises a ring-shaped section configured to abut the studded joint member.  
   
   
       47 . The mold system of  claim 46 , wherein the mold injection nozzle is configured for pressurably injecting the desired mold material against the studded joint member to force the studded joint member sealingly against the first centering structure.  
   
   
       48 . The mold system of  claim 43 , comprising a spring-loaded assembly configured to abut the support structure.  
   
   
       49 . The mold system of  claim 43 , wherein the second centering structure comprises a plurality of centering tabs.  
   
   
       50 . The mold system of  claim 49 , wherein the plurality of centering tabs comprises geometry configured to facilitate a desired thickness of the desired mold material about the studded joint member.  
   
   
       51 . The mold system of  claim 50 , wherein the plurality of centering tabs comprises at least three symmetrically arranged tabs, which are configured to contact the support structure.