Abstract:
A new and novel suspension link for the suspension system of vehicles, which is easily removed and replaced in a repair mode. More specifically, there is an vehicle sway bar stabilizer link that has angle capability for replacing prior art suspension links having ball-type devices which comprise a polished steel ball surround by a steel liner, or a polished steel ball surrounded by a plastic liner. A method of manufacture is also disclosed.

Description:
BACKGROUND OF THE INVENTION 
     Suspension sway bar systems are designed to absorb road shock and variable dynamic loads which, if not controlled, lead to poor handling and unsafe vehicle performance. Suspension components are subjected to harsh environments such as moisture, salt, road debris and dirt, all of which have detrimental effects on each of the individual components, but mostly on the metallic components. Currently, different designs are used to provide a stabilizer link. 
     The invention disclosed herein deals with a new and novel suspension link for the suspension systems of vehicles, which is easily removed and replaced in a repair mode. More specifically, the present invention relates to an automotive sway bar stabilizer link that has angle capability for replacing suspension links having ball-type devices which comprise a polished steel ball surround by a steel or a plastic liner with a steel backing. 
     One such ball joint type component is shown in U.S. Pat. No. 6,019,383. This type of device is advantageous, in that, it provides rotatability of the ball and angular movement of the through bolt (rod) part. 
     Such a device has many deficiencies, however, such as minimal preload on the steel ball, steel-to-steel contact, along with no provision for lubrication as a means to extend life, and poor sealing of internal parts by a seal or a boot. Intrusion of foreign material causes rust and degradation of the internal parts resulting in accelerated wear, noise and excessive clearance which leads to reduced vehicle control and the need for a complete replacement at substantial cost. If the steel is built with a plastic liner, the tendency of the steel is to degrade the plastic which leads to the same problems discussed just Supra. 
     It is therefore desirable to provide an alternative device that reduces the deficiencies of the prior art products. Such ball type suspension systems have a history of being very difficult to replace when they have been essentially destroyed or fail to continue to work properly. The instant invention overcomes the problems of repair and replacement of such suspension link bars. 
     THE INVENTION 
     What is disclosed and claimed herein is a new and novel link for vehicle suspensions systems. The link comprises a riser, the riser having a top, a bottom, and two sides. 
     The riser top has an opening through it, there being a threaded stud attached to the bottom of riser such that the threaded portion of said stud is outside of the riser, the threaded stud has a distal end. 
     There is a link assembly, the link assembly comprising a rod having a near end and a distal end, wherein the near end is surmounted by a fixed hex cap and the distal end of said rod is threaded, said rod being of a predetermined length and diameter. 
     The rod has a first concave washer surmounted on the bottom of the hex cap and on the rod, the first concave washer being surmounted by a first bushing having a convex surface. 
     There is a second bushing mounted on the rod and surmounted on the top of the riser with a second concave washer mounted on the rod and surmounting the second bushing. 
     There is a sleeve, having a top end, mounted on the rod and surmounted on the top of the second concave washer with a third concave washer mounted on the rod and surmounted on the top end of the sleeve, the second concave washer being surmounted by a barbell bushing mounted on the rod, said barbell bushing being surmounted by a fourth concave washer. The threaded distal end of the rod has threadably affixed thereto, a lock nut wherein the diameter of the rod is substantially smaller in diameter than the diameter of the opening in the top of the riser. 
     In another embodiment of this invention, there is A method of manufacturing a riser for a link used in vehicle suspension systems. The method comprises providing a flat metal plate having a predetermined size and thickness, a center point, two terminal ends, and a horizontal flat bottom surface. 
     There is a dome formed, having predetermined dimensions, from the bottom of the flat plate and at the center point, the dome having a center point and a formed edge. 
     Thereafter, forming an opening through the flat plate at the center point of the dome and bending the flat plate at a predetermined distance from the formed edge of the dome of the flat plate to form a bent plate, this bend being in the range of 90° to 120°, the preferred bend being about 110°. 
     There is a second bend made in the flat plate a predetermined distance from the formed edge of the dome, this bend being in the range of from 100° to 120°. A bend of about 112° being preferred. 
     Thereafter, forming a third bend of the flat plate a predetermined distance from the formed edge of the dome, essentially at the formed edge of the dome, the bend being in the range of from 100° to 125°, wherein all of the angles of the bends are determined from the horizontal bottom surface of the flat plate, the preferred bend being about 115°. 
     Thereafter, bending the bent plate until the terminal ends touch, and then welding the terminal ends together, the welded terminal ends forming a bottom surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a full view of an assembled suspension link of this invention. 
         FIG. 2  is a fully exploded view of a suspension link of this invention. 
         FIG. 3  is a full top view of the riser showing the substantially larger opening in the top along with the smaller opening in the bottom. 
         FIG. 4  is a full view of an assemble suspension link of this invention in full angle from the vertical. 
         FIG. 5A  is a full side view of another embodiment of a riser of this invention. 
         FIG. 5B  is a full side view of another embodiment of this invention showing the riser with the stud attached to a corner of the riser. 
         FIG. 5C  is a full side view of another embodiment of this invention showing the riser with the stud attached to one of the sides of the riser. 
         FIG. 6  is a full side view of a washer of this invention. 
         FIG. 7  is a full side view of a bushing of this invention. 
         FIG. 8  is a 3-D illustration of a riser of this invention. 
         FIG. 9A  is an illustration of a flat plate used in the method of this invention. 
         FIG. 9B  is an illustration of a dome and opening provided in the flat plate. 
         FIG. 9C  is an illustration of the first bend of the flat plate, wherein the bend is about 111° calculated from the horizontal bottom surface of the flat plate. 
         FIG. 9D  is an illustration of the second bend of the flat plate, wherein the bend is about 115° calculated from the horizontal bottom surface of the flat plate. 
         FIG. 9E  is an illustration of the third bend of the flat plate, wherein the bend is about 115° calculated from the horizontal bottom surface of the flat plate. 
         FIG. 9F  is an illustration of the flat plate bent until the terminal ends meet, along with an illustration of attaching the threaded stud to the bottom surface of the terminal ends. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Turning now to the device of this invention and  FIG. 1 , there is shown a fully assembled suspension link  1  comprising a riser  2 . The riser  2  operates as the dividing line between the fully stabilized bottom portion of the link  1  and the angularity of the top portion of the link  1 . 
     The riser  2  has a top  3 , a bottom  4 , and two sides  5  and  6  and the bottom  4 . The bottom  4  has a threaded stud  9  attached to it such that the threaded portion  23  is located outside of the riser  2 . There is a bushing  29  fitted onto the threaded stud  9  that interfaces with the bottom surface  30  of the riser  2 . The bushings size is determined by the link size and is generally in the range of from about inch to about 3 inches in diameter. 
     The size of the riser  2  is determined by the model and type of vehicle that the link is to be used on, for example, in a car, the riser  2  is generally about 2 to 4 inches in breadth and height, while in snowmobiles and ATV&#39;s, the size of the riser  2  is substantially less. A large truck would normally have a riser  2  in excess of 4 inches in breadth and height. At the every minimum, the rise has to be large enough to accommodate the end of the rod  11 , a nut, a washer, and a bushing. 
     The identification of the bushings as “barbell” herein is just to differentiate such bushings from the other bushings of the device. It should be understood that the barbell bushing can be one piece, or it can be two separate pieces. When in place on the threaded rod, it resembles a barbell. 
     It is contemplated within the scope of this invention to attach the stud  9  to any outside surface of the riser  2 , and as shown in  FIG. 5B , it is attached to one point of the riser  2  and in  FIG. 5C , it is attached to one of the sides. It can be attached at any point around the riser  2  to accommodate putting an angle in the link to fit various models of vehicles, including snowmobiles, ATV&#39;s, cars, trucks, and the like 
     The riser  2  has an opening  8  (shown in phantom, see also  FIG. 3 ) through it. There is a link assembly  10  and the link assembly  10  comprises a rod  11  having a near end  12  and a distal end  13 . The near end  12  is surmounted by a fixed hex cap  14  that can be used to turn the rod  11  or can be used with a wrench to help tighten a lock nut  15  on the distal end  13  of the rod  11 , such lock nut  15  being discussed infra. The hex cap  14  has a bottom surface  16  from which the rod  11  extends. The distal end  13  of the rod  11  is threaded to receive a lock nut  15 . The length of the rod  11  is predetermined so as to fit various vehicles and the length of the rod allows designs that are essentially unlimited in length. For purposes of this invention, rod lengths from about ½ inch to about 14 inches is preferred. The same is true of the diameter of the rod  11 , as the diameter of the rod  11  is based on the diameter of the opening  8  wherein the diameter of the rod  11  is substantially less than the diameter of the opening  8  so that the rod  11  can be moved laterally and circuitously within the opening  8 . Typically, the diameter of the rod  11  is about to ½ to ¼ of the diameter of the opening  8 . 
     The washers useful in this invention are hyperbolic discs in which the inside surface  17  is concave and the outside surface  18  is convex. The washers can be manufactured from metals, fiber filled carbon, cross linked plastics such as polyethylene, cast urethane polymers, and the like. 
     The rod  11  has a first washer  19  which is mounted on the rod  11  and is surmounted on the bottom  16  such that the outside surface  18  faces the bottom  15  and the inside surface  17  faces a bushing  20 . 
     Bushings in this invention may be manufactured from elastomer, rubber, or hard foam rubber. Specifically, the bushings may comprise poured or cast urethane polymer. It will be appreciated that any suitable material may be used for the bushings of this invention. Other polymeric or rubber materials may be suitable. In some embodiments, such as shown in the instant device, it is preferred that the concave surfaces  21  and the convex surfaces  22  of the bushings be relatively smooth. In some embodiments it is preferred that the bushings have a Durometer of between about 45 and 90 on the Shore A scale. It will be appreciated that any suitable hardness may be used. The Durometer and size of the bushings may be adjusted to optimize the performance of the link assembly. 
     The bushings are continually preloaded by the rod  11  to absorb and dampen various suspension impact loads. Further, by using an elastomeric bushing adjacent a metal link member, the device requires no lubrication and provides relatively quiet operation as compared with prior art ball type linkage assemblies. The constant preload absorbs impact loads and minimizes any clearance between the bushing, link member, and other suspension components with which the link assembly may be secured. The bushings may contact the other suspension components to which the link assembly may be secured. 
     After the rod  11  is passed through the opening  8  from inside the riser  2 , it is surmounted by a second bushing  24  wherein the concave surface  21  is fitted to the top of the riser  2 . The second bushing  24  is then surmounted by a second washer  25  such that the concave surface  17  fits onto the top surface of the second bushing  24 . 
     There is a sleeve  26  that slips onto the rod  11  and is surmounted on the second washer  25 . At the top of the sleeve  26  there is mounted a third washer  27  that also slips over the rod  11  with the concave surface  17  facing a barbell bushing  28 . Surmounting the third washer  27  is the barbell bushing  28  and surmounting the barbell bushing  28  is a fourth washer  29 . It should be noted that the forth washer  29  is mounted such that the concave surface  17  is facing the barbell bushing  28 . 
     The fourth washer  29  is then surmounted by the lock nut  15  and the entire link assembly  10  is tightened down. 
       FIG. 3  shows a full top view of the riser  2  in which there is shown the opening  8 . 
     Turning now to  FIG. 2 , there is shown an exploded view of the assembly of  FIG. 1 , showing how the components parts relate to each other. The numbered designations in  FIG. 2  are the same as in  FIG. 1 . 
     In both  FIGS. 1 and 2 , the link assembly is shown in straight vertical alignment while in  FIG. 4 , the link assembly is shown at an angle from the straight vertical alignment. The number designations in  FIG. 4  are the same as in  FIG. 1 . 
     In  FIG. 5A , which is a full side view of another embodiment of the invention there is shown the riser  2  in which the side wall  5  is shorter than the side wall  6 . This configuration supports the assembly of the device as the variable length of the side walls allows for the convenient insertion of the rod  11  and also helps to determine the angle of the link with regard to the threaded stud  9 . 
     Aside from the bushings which have been described in detail Supra, the link assembly of this invention is manufactured from metals, and the most preferred metal is steel. 
     This inventive device provides a capability for the link to be angled to simulate the prior art ball and socket while providing a device that is easy to refurbish when needed simply by removing the rod  11  and rebuilding the assembly. 
     Using a simple rod through the bushing and the link member makes the link assembly easily rebuildable by simply removing the rod and replacing the bushings. The rod can then be reinserted to attach the link assembly with the vehicle suspension. 
     Turning now to the method of this invention, and with regard to  FIGS. 9A to 9F , there is shown the steps in manufacturing a device of this invention. 
       FIG. 9A  is an illustration of a flat plate  31  of this invention showing a horizontal flat bottom surface  32  and terminal ends  33  and  33 ′.  FIG. 9B  illustrates the flat plate  31  with a dome  34  formed in the metal from the bottom flat surface  32 , upwardly. Also shown in phantom is the opening  35  formed in the center point  36  of the dome  34 . 
       FIG. 9C  is an illustration of the first bend  37  in the flat plate  31 , at point  38 . In addition,  FIG. 9D  illustrates the second bend  39 , at point  40 . 
       FIG. 9E  illustrates the third bend  41 , at points  42  and the bending of the flat plate  31  until the terminal ends  33  and  33 ′ meet, although, in the illustration, the ends  33  and  33 ′ do not meet for clarification reasons. It is important at this point that this third bend and the complete bend be made without torqueing the dome  34  and bending the dome  34  downward, as the dome  34  should remain round in order for the link to operate smoothly. 
       FIG. 9F  illustrates the complete bending of the flat plate  31  to form the riser. In addition, there is shown the attachment of the threaded stud  9 . Shown are weld points  43  at the bottom surface  44  of the terminal ends  33  and  33 ′( 44  shown in  FIG. 9E ). 
     The riser can be fully formed and welded and then the threaded stud  9  can be welded on, or the threaded stud  9  can be welded on at the same time that the two terminal end  33  and  33 ′ are welded together.