Connector with insert molded captive ball

• US 5,676,484 A
• Filed: 01/08/1997
• Issued: 10/14/1997
• Est. Priority Date: 05/22/1995
• Status: Expired due to Fees

• Current Assignee: AVM Industries, Inc.
• Original Assignee: AVM Software Incorporated (Paltalk, Inc.)
• Inventors: Laws, David, Chamberlin, James B.
• Primary Examiner(s): Knight, Anthony
• Application Number:
  US08/780,713
• Time in Patent Office: 279 Days
• Field of Search: 403/122, 403/123, 403/119, 403/76, 403/77, 403/150, 264/242, 264/110, 264/130, 29/898.048, 29/898.049, 29/898.05
• US Class Current: 403/122
• CPC Class Codes: F16C 11/0614 the female part of the joint being open on two sides
• CPC Class Codes: F16C 11/0657 the socket member being mainly made of plastics
• CPC Class Codes: Y10T 29/49661 Nonmetallic socket
• CPC Class Codes: Y10T 403/32196 Articulate joint is ball and socket
• CPC Class Codes: Y10T 403/32631 Universal ball and socket

Abstract

A connector assembly with a connector body molded directly about a captive ball formed on a separate shaft, where the shaft and connector are attached to separate bodies which move relative to each other. This assembly retains an essentially zero clearance fit between the ball and the connector so as to prevent rattling between the parts from vibrations. This zero clearance fit is achieved at a much lower cost than comparable quality connectors due to higher diametric tolerances for the ball component. Higher diametric tolerances do not affect the final fit because the connector is molded directly about the ball.

Claims

1. An improved captive ball and connector assembly adapted for use where the assembly will be subjected to rattle inducing vibrations, such as when utilized in the passenger compartments of automobiles, and any resulting rattling would pose a problem for customers and end users and where mass production of the assembly at minimal production costs is a key customer goal, the improved assembly comprising:

a shaft including a ball portion and a first reduced diameter neck portion that is adjacent to the ball portion, with the shaft having a longitudinal axis, with the ball portion having a radially outwardly facing, substantially spherical surface portion that is defined between a first plane, which is disposed at an angle with respect to the longitudinal axis of the shaft and which is adjacent to the first neck portion, and a second plane, which is disposed at a similar angle with respect to the longitudinal central axis of the shaft; and

that has a diameter greater than the first neck portion;

an end connector subassembly comprising an attachment rod, which has a mounting end, and a one piece molded plastic connector body, with the connector body having a proximal end and a distal end to which the mounting end of the attachment rod is attached, with the proximal end of the connector body including a ball containing cavity molded about at least part of the spherical surface portion, with the ball containing cavity having a diameter substantially equal to the diameter of the spherical surface portion so that essentially a zero clearance fit is achieved between the ball containing cavity and the spherical surface portion thereby eliminating rattling between the spherical surface position and the ball containing cavity when the assembly is subject to vibration; and

an annular retaining washer that is disposed about the shaft adjacent to the first neck portion, with the retaining washer having a first surface which is in surface to surface contact with a spherical zone of the spherical surface portion, adjacent to the first plane and about the longitudinal axis of the shaft, with the first surface of the retaining washer being held against the spherical surface portion while the connector body is being molded about the spherical surface portion and during use of the assembly, and with the retaining washer serving to form a seal with the spherical surface portion so as to prevent the flow of plastic between the spherical surface portion and the retaining washer during the molding of the connector body.

2. The improved assembly of claim 1 wherein the distal end of the connector body includes a rod cavity for receiving the mounting end of the attachment rod, with the rod cavity opening originating in the center of the most distal end of the connector body and extending proximally forward towards the ball cavity.

3. The improved assembly of claim 2 wherein the rod cavity includes a proximal end and;

wherein a relatively thick layer of molded plastic material remains between the proximal end of the rod cavity and the ball portion.

4. The improved assembly of claim 3 wherein the mounting end of the attachment rod includes a plurality of barbs which protrude outwards for securely mounting the attachment rod into the rod cavity.

5. The improved assembly of claim 4 wherein the attachment rod mounting end terminates in a concave surface which faces the spherical surface portion;

and wherein the concave surface has a spherical radius approximately equal to that of the spherical surface portion.

6. The improved assembly of claim 3 wherein the rod cavity is threaded;

and wherein the mounting end of the attachment rod;

is similarly threaded, for securely mounting the attachment rod into the rod cavity.

7. The improved assembly of claim 6 wherein the attachment rod mounting end terminates in a concave surface which is perpendicular to the longitudinal axis of the attachment rod;

and wherein the concave surface has a spherical radius approximately equal to that of the spherical surface portion.

8. The assembly of claim 3 wherein the attachment rod has a longitudinal axis;

wherein the mounting end of the attachment rod terminates in a concave surface which faces the spherical surface portion and wherein the concave surface has a spherical radius approximately equal to that of the spherical surface portion.

9. The improved assembly of claim 1 wherein the shaft has a first end adjacent to the first neck portion and a second end defined by the second plane;

and wherein the second end defines a flat surface which includes a recess for receiving a tool for rotating the shaft about its longitudinal axis.

10. The improved assembly of claim 1 wherein the connector body further includes:

a top and bottom surface;

a circumferential lip on each of the top and bottom surfaces, with each lip surrounding the ball containing cavity, and with each lip flaring towards the distal end of the connector body to create a gradual transition between the distal end and the proximal end of the molded connector body.

11. The assembly of claim 1 wherein the shaft has a first end adjacent to the first neck portion;

wherein the shaft has a second neck portion adjacent to the second plane; and

wherein the shaft has a second end adjacent to the second neck portion.