Extruded suspension linkage

A suspension linkage for a motor vehicle includes an extruded body having a first wall and a longitudinal length. An extruded feature is disposed on the first wall of the extruded body and extends along the longitudinal length. The extruded feature has a cross-sectional profile configured to control a flexural rigidity of the suspension linkage.

FIELD

The invention relates generally to an extruded suspension linkage for a motor vehicle, and more particularly to an extruded suspension linkage for a motor vehicle having a reinforcement feature that has a cross-sectional profile configured to control a flexural rigidity of the extruded suspension linkage.

BACKGROUND

A typical motor vehicle has numerous metal linkages that connect one member to another. For example, a specific category of metal linkages include suspension linkages used in the suspension system of motor vehicles. Suspension linkages generally connect components of the motor vehicle drive unit, such as wheels or axles, to the body or frame of the motor vehicle in order to transmit static and dynamic loads there between. For example, suspension linkages may include upper and lower control arms, tension linkages, longitudinal linkages, transverse linkages, forward or rear spring arms, etc. The suspension linkages are typically connected to the members of the motor vehicle via bearings to allow relative movement of the components of the suspension system and the frame of the motor vehicle.

In the past, these suspension linkages were made from stamped steel parts, assembled, and pressed into their final shapes. To reduce weight, these suspension linkages have more recently been made from forged/cast aluminum pieces which are welded together to form the final part or from extruded aluminum or other extruded metals or alloys. Extruded suspension linkages have the advantage of not requiring welds and generally reduce the post-processing requirements of the suspension linkage. While these extruded suspension linkages are useful for their intended purpose, it is difficult to control the flexural rigidity and strength of the suspension linkage while simultaneously minimizing weight and meeting packaging and tolerance requirements. Accordingly, there is a need in the art for an extruded suspension linkage that meets these requirements.

SUMMARY

A suspension linkage for a motor vehicle is provided. The suspension linkage includes an extruded body having a first wall and a longitudinal length. An extruded feature is disposed on the first wall of the extruded body and extends along the longitudinal length. The extruded feature has a cross-sectional profile configured to control a flexural rigidity of the suspension linkage.

In one aspect, the extruded feature is a rib.

In another aspect, the rib is disposed on an inner surface of the first wall of the extruded body and the rib extends out from the inner surface of the first wall.

In yet another aspect, the rib extends along the entire longitudinal length of the first wall.

In yet another aspect, the first wall has a wall width and the rib has a rib width and the rib width is less than the wall width.

In yet another aspect, the rib width is less than half the wall width.

In yet another aspect, the rib is located on an outer surface of the first wall of the extruded body and the rib extends out from the outer surface.

In yet another aspect, the extruded body further includes a second wall and a third wall that connects the first wall to the second wall, and wherein an outer surface of the first wall is convex.

In yet another aspect, the extruded feature is a groove formed in the first wall of the extruded body.

In yet another aspect, the groove is formed in an inner surface of the first wall of the extruded body and the groove extends into the inner surface, and wherein the groove has a width less than a width of the first wall.

In yet another aspect, the groove is formed in an outer surface of the first wall of the extruded body and the groove extends into the outer surface, and wherein the groove has a width less than a width of the first wall.

In yet another aspect, the extruded body includes a first end portion disposed longitudinally opposite a second end portion, wherein the first end portion is connectable to a suspension unit and the second end portion is connectable to a frame of the motor vehicle.

Further aspects, examples, and advantages will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature.

DETAILED DESCRIPTION

With reference toFIGS. 1 and 2, an extruded suspension linkage is generally indicated by reference number10. The extruded suspension linkage10may be configured as an upper or lower control arm, a tension linkage, a longitudinal linkage, a transverse linkage, a forward or rear spring arm, etc. The extruded suspension linkage10generally includes a body12. The body12is formed from an extruded metal or alloy and then subjected to post-processing to produce particular features which will be described below. In one example, the body12is generally formed from extruded aluminum. In another example, the body12is formed from extruded magnesium. In addition, it should be appreciated that the body12may be made from various other suitable extrudable metals or alloys.

In the example provided, the body12is formed as an elongated, rectangular tube having a top wall14, a bottom wall16, a first side wall18, and a second side wall20. However, the body12may have other profile configurations so long as the body12includes at least one wall. For example, the body12may have a hat shaped profile, an open “C”-shaped profile with a gap between walls, a cylindrical profile, etc. The body12further includes a first end portion22and a second end portion24disposed longitudinally opposite the first end portion22.

The first end portion22is configured to be attached to a component of a suspension unit (not shown) and includes first and second holes26,28formed in the first and second side walls18,20, respectively. The first and second holes26,28may be cut or punched into the body12during post-processing. The second end portion24is configured to be attached to a body frame (not shown) of a motor vehicle and includes mounting holes30and32formed in the first side wall20, mounting holes34and36formed in the second side wall22, and “v” shaped slots38,39formed in the top and bottom walls14,16, respectively. It should be appreciated that the body12may include additional features to accommodate particular installation configurations.

The body12may be bent or curved in post-processing so that one or more of the walls14,16,18,20may be concave and an opposite wall is convex. In the example provided, the body12is bent such that an outer surface40of the body12is concave along the top wall14while the outer surface40is convex along the bottom wall16.

The extruded suspension linkage10further includes an extruded reinforcement feature50formed on the body12. The extruded reinforcement feature50has a cross-sectional profile configured to control a flexural rigidity of the extruded suspension linkage10. Generally, the extruded reinforcement feature50is comprised of a rib52that increases the thickness of one of the walls14,16,18, and20. The rib52is formed on the extruded suspension linkage10during the extrusion process. In the example provided, the rib52is disposed on an inner surface54of the first wall14. Preferably, the rib52is disposed on whichever of the walls14,16,18, and20is convex in order to maximize the strength or flexural rigidity of the extruded suspension linkage10. In addition, locating the rib52on the inner surface54minimizes the impact on packaging of the extruded suspension linkage10. The rib52has a substantially rectangular cross-section and has a height “h” and a width “w”. However, the rib52may have other cross-sectional profiles without departing from the scope of the present invention. The width w of the rib52is less than a width “W” of the top wall14, as shown inFIG. 2. In a preferred embodiment, the width w of the rib52is less than half the width W of the top wall14. The rib52extends longitudinally along the length of the first wall14from the first end portion22to the second end portion24. In addition, the rib52is preferably centered on the first wall14to balance forces.

Turning toFIG. 3, a graph illustrates the relationship between the width w of the rib52, the height h of the rib52, and the flexural rigidity of the extruded suspension linkage10. Generally, increasing the rib width w and the rib height h increases the flexural rigidity of the extruded suspension linkage10. Thus, the flexural rigidity of the extruded suspension linkage10can be adjusted by simply changing the dimensions of the rib52. Fine tuning the flexural rigidity of the extruded suspension linkage10by changing the dimensions of the rib52allows for quick adjustments to accommodate different load requirements for a given application.

Turning now toFIG. 4, an alternate extruded suspension linkage is generally indicated by reference number110. The extruded suspension linkage110is similar to the extruded suspension linkage10shown inFIGS. 1-2and therefore like components are indicated by like reference numbers. However, in the extruded suspension linkage110, the rib52is formed on the outer surface40of the first wall14.

Turning toFIG. 5, yet another alternate extruded suspension linkage is generally indicated by reference number210. The extruded suspension linkage210is similar to the extruded suspension linkage10shown inFIGS. 1-2and therefore like components are indicated by like reference numbers. However, the extruded suspension linkage210includes an extruded feature250. The extruded feature250has a cross-sectional profile configured to reduce a flexural rigidity of the extruded suspension linkage210. Generally, the extruded feature250is comprised of a groove252that decreases the thickness of one of the walls14,16,18, and20. The groove252is formed on the extruded suspension linkage10during the extrusion process. In the example provided, the groove252is disposed on an inner surface54of the first wall14. However, the groove252may be disposed on the outer surface40and on any of the walls16,18,20. The groove252may have various cross-sectional profiles without departing from the scope of the present invention. The groove252has a width “w” and a depth “d”. The width w of the groove252is less than a width “W” of the wall. In a preferred embodiment, the width w of the groove252is less than half the width W of the wall. The groove252extends longitudinally along the length of the first wall14from the first end portion22to the second end portion24. The groove252functions in a manner similar to that of the rib52but can be considered to reduce the flexural rigidity of the extruded suspension linkage10by removing material rather than adding material.