Patent Description:
A suspension system is disclosed in <CIT>. <CIT> discloses a vehicle chassis that incorporates an antisway bar assembly that includes a horizontally extending antisway bar that has ends that are received in mounting arrangements that are mounted to the underside of lower air bag mounting brackets. <CIT> discloses a steerable independent front suspension that does not include a stabilizer bar subassembly.

According to the invention, a suspension system is provided as set out in claim <NUM>.

Referring to <FIG>, portion of a vehicle <NUM> is shown. The vehicle <NUM> may be a motor vehicle like a truck, bus, farm equipment, military transport or weaponry vehicle, or cargo loading equipment for land, air, or marine vessels. The vehicle <NUM> may include a frame <NUM>, a suspension system <NUM>, a wheel end assembly <NUM>, a brake subsystem <NUM>, a steering subsystem <NUM>, and a stabilizer bar subassembly <NUM>.

The frame <NUM> may help provide the structure of the vehicle <NUM>. In at least one configuration, the frame <NUM> may include structural members such as frame rails, cross rails that interconnect the frame rails, or the like. The frame rails may extend longitudinally or in a direction that may extend between the front and rear of the vehicle <NUM>. The cross rails may extend laterally between the frame rails and may be fixedly attached to the frame rails. The frame <NUM> may support components of the vehicle <NUM>. For example, the frame may support a vehicle drivetrain and a cab or cabin of the vehicle <NUM> that may have a passenger compartment that may receive a driver. The frame <NUM> may also facilitate mounting of the suspension system <NUM> to the vehicle <NUM>.

Referring to <FIG>, the suspension system <NUM> may connect one or more wheel end assemblies <NUM> to the frame <NUM>. In addition, the suspension system <NUM> may dampen vibrations associated with vehicle travel, provide a desired level of ride quality, control vehicle ride height, or combinations thereof. The suspension system <NUM> may be an independent suspension system that may allow wheels to move up and down independently with respect to each other or without influence from another wheel. <FIG> show a portion of the suspension system <NUM> that is associated with a single wheel; however, is it to be understood that the suspension system <NUM> may be associated with multiple wheels. For instance, the components of the suspension system <NUM> that are shown in <FIG> may be provided with a wheel like a right front wheel when viewed from a position in front of the vehicle. These components may also be provided as a mirror image when provided with an opposing wheel like a left front wheel. It is also contemplated that the suspension system <NUM> or components of the suspension system discussed below are not necessarily limited to use with front wheels of a vehicle. In at least one configuration, the suspension system <NUM> includes a steering knuckle <NUM>, a knuckle carrier <NUM>, an upper control arm <NUM>, a platform <NUM>, and one or more air springs <NUM>, and may include a brake spider <NUM>, a lower control arm <NUM>, and one or more shock absorbers <NUM>.

Referring to <FIG>, the steering knuckle <NUM> may interconnect the wheel end assembly <NUM> to the knuckle carrier <NUM>. The steering knuckle <NUM> is rotatable about a first axis <NUM> with respect to the knuckle carrier <NUM>, the upper control arm <NUM>, and the lower control arm <NUM> to steer or change the direction of travel of the vehicle <NUM>. As an example, the steering knuckle <NUM> may receive and may rotate about a kingpin <NUM> that may extend along the first axis <NUM> and may be fixedly disposed on the knuckle carrier <NUM>. The steering knuckle <NUM> may be operatively connected to the steering subsystem <NUM> as will be discussed in more detail below.

The steering knuckle <NUM> may facilitate mounting of the wheel end assembly <NUM> and the brake subsystem <NUM>. For example, the steering knuckle <NUM> may have a spindle <NUM> that may rotatably support the wheel end assembly <NUM>. The spindle <NUM> may support one or more wheel bearings that rotatably support a hub of the wheel end assembly <NUM> and allow the hub and an associated wheel to rotate about a second axis <NUM>. In a drive axle configuration, the axle may extend through the spindle <NUM> and may provide torque to a corresponding hub and wheel. The steering knuckle <NUM> may also facilitate mounting of the brake spider <NUM>.

The brake spider <NUM> may facilitate mounting of the brake subsystem <NUM> to the steering knuckle <NUM>. For example, a portion of the brake subsystem <NUM>, such as a brake caliper, may be fixedly mounted to the steering knuckle <NUM>. The brake spider <NUM> may be fixedly disposed on the steering knuckle <NUM> in any suitable manner. For instance, the brake spider <NUM> may be mounted to the steering knuckle <NUM> with a plurality of fasteners, such as bolts.

Referring to <FIG>, <FIG> and <FIG>, the knuckle carrier <NUM> may interconnect the steering knuckle <NUM> to the upper control arm <NUM> and the lower control arm <NUM>. In at least one configuration, the knuckle carrier <NUM> includes a mounting stem <NUM> and may include a first side <NUM>, a second side <NUM>, an upper hole <NUM>, a lower hole <NUM>, a shock absorber mount <NUM>, a neck portion <NUM>, and a connecting web <NUM>.

The first side <NUM> may face toward the front of the vehicle <NUM>.

The second side <NUM> may be disposed opposite the first side <NUM>. As such, the second side <NUM> may face toward the rear of the vehicle <NUM>.

The upper hole <NUM> may extend between the first side <NUM> and the second side <NUM>. The upper hole <NUM> may facilitate mounting of the upper control arm <NUM>. For example, the upper hole <NUM> may be a through hole and may receive a pivot mechanism <NUM> that pivotally connects the upper control arm <NUM> to the knuckle carrier <NUM> as will be discussed in more detail below.

Referring to <FIG>, a cross-sectional view through the center of the upper hole <NUM> is shown. The upper hole <NUM> may be defined by multiple surfaces or features of the knuckle carrier <NUM>, such as an intermediate portion <NUM>, a first bearing support surface <NUM>, and a first step surface <NUM>. The upper hole <NUM> may also be defined by a second bearing support surface <NUM>, a second step surface <NUM>, a first seal support surface <NUM>, a first outer step surface <NUM>, a second seal support surface <NUM>, and/or a second outer step surface <NUM>.

The intermediate portion <NUM> may be disposed proximate the center of the upper hole <NUM>. The intermediate portion <NUM> may have a smaller diameter than the first bearing support surface <NUM> and the second bearing support surface <NUM>.

The first bearing support surface <NUM> may be axially positioned between the first side <NUM> and the intermediate portion <NUM>. For example, the first bearing support surface <NUM> may be axially positioned between the first step surface <NUM> and the first outer step surface <NUM>. The first bearing support surface <NUM> may have a larger diameter than the intermediate portion <NUM>.

The first step surface <NUM> may extend from the intermediate portion <NUM> to the first bearing support surface <NUM>. For instance, the first step surface <NUM> may extend from a first end of the intermediate portion <NUM> to an end of the first bearing support surface <NUM>. The first step surface <NUM> may be disposed substantially perpendicular to a center axis <NUM> of the upper hole <NUM>.

The second bearing support surface <NUM> may be axially positioned between the second side <NUM> and the intermediate portion <NUM>. For example, the second bearing support surface <NUM> may be axially positioned between the second step surface <NUM> and the second outer step surface <NUM>. The second bearing support surface <NUM> may have a larger diameter than the intermediate portion <NUM>. In addition, the second bearing support surface <NUM> may optionally have the same diameter as the first bearing support surface <NUM>.

The second step surface <NUM> may extend from the intermediate portion <NUM> to the second bearing support surface <NUM>. For instance, the second step surface <NUM> may extend from a second end of the intermediate portion <NUM> that may be disposed opposite the first bearing support surface <NUM> to an end of the second bearing support surface <NUM>. The second step surface <NUM> may be disposed substantially perpendicular to the center axis <NUM>.

The first seal support surface <NUM> may be axially positioned between the first side <NUM> and the first bearing support surface <NUM>. For instance, the first seal support surface <NUM> may be axially positioned between the first side <NUM> and the first outer step surface <NUM>. The first seal support surface <NUM> may have a larger diameter than the first bearing support surface <NUM>.

The first outer step surface <NUM> may extend from the first bearing support surface <NUM> to the first seal support surface <NUM>. For example, the first outer step surface <NUM> may extend from an end of the first bearing support surface <NUM> that is disposed opposite the first step surface <NUM> to an end of the first seal support surface <NUM>. The first outer step surface <NUM> may be disposed substantially perpendicular to the center axis <NUM>.

The second seal support surface <NUM> may be axially positioned between the second side <NUM> and the second bearing support surface <NUM>. For instance, the second seal support surface <NUM> may be axially positioned between the second side <NUM> and the second outer step surface <NUM>. The second seal support surface <NUM> may have a larger diameter than the first bearing support surface <NUM>. In addition, the second seal support surface <NUM> may optionally have the same diameter as the first seal support surface <NUM>.

The second outer step surface <NUM> may extend from the second bearing support surface <NUM> to the second seal support surface <NUM>. For example, the second outer step surface <NUM> may extend from and end of the second bearing support surface <NUM> that may be disposed opposite the second step surface <NUM> to an end of the second seal support surface <NUM>. The second outer step surface <NUM> may be disposed substantially perpendicular to the center axis <NUM>.

The lower hole <NUM> may extend between the first side <NUM> and the second side <NUM>. In addition, the lower hole <NUM> may be disposed proximate the bottom of the knuckle carrier <NUM>. As such, the lower hole <NUM> may be disposed below the upper hole <NUM>, mounting stem <NUM>, shock absorber mount <NUM>, neck portion <NUM>, in the connecting web <NUM>. The lower hole <NUM> may facilitate mounting of the lower control arm <NUM>. For example, the lower hole <NUM> may be a through hole that may receive a pivot mechanism that pivotally connects the lower control arm <NUM> to the knuckle carrier <NUM>.

The mounting stem <NUM> may be disposed between the first side <NUM> and the second side <NUM>. The mounting stem <NUM> may intersect or may be disposed along a center plane <NUM> of the knuckle carrier <NUM>. The center plane <NUM> may be a vertical plane that may generally bisect the knuckle carrier <NUM>.

The shock absorber mount <NUM> may facilitate mounting of a shock absorber <NUM> as will be discussed in more detail below. The shock absorber mount <NUM> may be disposed below the upper hole <NUM> and above the lower hole <NUM>. The shock absorber mount <NUM> may have a first mounting tab <NUM> and a second mounting tab <NUM>.

The first mounting tab <NUM> may extend from or protrude from the first side <NUM> of the knuckle carrier <NUM>. The first mounting tab <NUM> may be disposed along a side of the knuckle carrier <NUM> that faces away from the neck portion <NUM>. The first mounting tab <NUM> may include a hole that may receive a fastener, such as a bolt, that may facilitate mounting of the shock absorber <NUM> to the knuckle carrier <NUM>. For example, a pivot mechanism may be mounted to the first mounting tab <NUM> and may facilitate pivotal movement of the shock absorber <NUM> with respect to the knuckle carrier <NUM>.

The second mounting tab <NUM> may be disposed opposite the first mounting tab <NUM>. As such, the second mounting tab on <NUM> may extend from or protrude from the second side <NUM> of the knuckle carrier <NUM>. The second mounting tab <NUM> may also be disposed along a side of the knuckle carrier <NUM> that faces away from the neck portion <NUM>. The second mounting tab <NUM> may include a hole that may receive a fastener that may facilitate mounting of the shock absorber <NUM> to the knuckle carrier <NUM> as previously discussed.

The neck portion <NUM> may facilitate mounting of the steering knuckle <NUM> to the knuckle carrier <NUM>. The neck portion <NUM> may be positioned below the upper hole <NUM> and above the lower hole <NUM>. In addition, the neck portion <NUM> may be positioned above the shock absorber mount <NUM>. The neck portion <NUM> may protrude from the knuckle carrier <NUM> toward the steering knuckle <NUM>. The neck portion <NUM> may include a kingpin hole <NUM> that may receive the kingpin <NUM>. One or more fastener holes <NUM> may extend through the neck portion <NUM> and may intersect the kingpin hole <NUM>. A fastener hole may receive a fastener <NUM>, such as a draw key, that may inhibit movement of the kingpin <NUM> along the first axis <NUM> with respect to the knuckle carrier <NUM>.

Referring to <FIG> and <FIG>, the connecting web <NUM> may extend from the upper hole <NUM> to the shock absorber mount <NUM>. As is best shown in <FIG>, the connecting web <NUM> may be asymmetrical and may be offset from the center plane <NUM> toward the first side <NUM> of the knuckle carrier <NUM>. As such, the connecting web <NUM> may extend to the first mounting tab <NUM> to partially define the first side <NUM> and may not extend to the second mounting tab <NUM>. As such, the connecting web <NUM> may partially define a clearance recess <NUM>. The clearance recess <NUM> may be disposed between the connecting web <NUM> and the second side <NUM> of the knuckle carrier <NUM>. The clearance recess <NUM> may extend from the second side <NUM> toward the first side <NUM> and may extend upward from the shock absorber mount <NUM> toward the upper hole <NUM>. The clearance recess <NUM> may extend upward to approximately the top of the neck portion <NUM> and may provide clearance for one or more components of the steering subsystem <NUM> when the steering knuckle <NUM> is rotated about the first axis <NUM>. The clearance recess <NUM> may help increase the total steering angle or range of rotation of the steering knuckle <NUM>.

Referring to <FIG> and <FIG>, an example of a pivot mechanism <NUM> is shown. The pivot mechanism <NUM> may rotatably connect or pivotally couple a control arm to the knuckle carrier <NUM>. The pivot mechanism <NUM> may be at least partially disposed in a hole in the knuckle carrier <NUM>. For example, the pivot mechanism <NUM> will be primarily described below in the context of being disposed in the upper hole <NUM> of the knuckle carrier <NUM> to facilitate rotation of the upper control arm <NUM>; however, it is contemplated that the pivot mechanism <NUM> could be employed in different locations or with different components. For instance, the pivot mechanism <NUM> may also be configured to couple the lower control arm <NUM> to a suitably configured lower hole <NUM> or may be used to couple the upper control arm <NUM>, lower control arm <NUM>, or both to the frame <NUM>. In at least one configuration, the pivot mechanism <NUM> may include a pin <NUM>, a first bearing assembly <NUM>, a second bearing assembly <NUM>, and a preload nut <NUM>. In addition, the pivot mechanism <NUM> may also include at least one seal, such as a first seal <NUM> and a second seal <NUM>.

The pin <NUM> may be partially received in the upper hole <NUM>. The pin <NUM> may extend along a pin axis <NUM> that may be coaxially disposed with the center axis <NUM> after assembly. In at least one configuration, the pin <NUM> may include a first end portion <NUM>, a second end portion <NUM>, a shoulder <NUM>, a center portion <NUM>, and a threaded portion <NUM>.

The first end portion <NUM> may extend from a first end surface of the pin <NUM>. The first end portion <NUM> may be disposed outside of the upper hole <NUM> and may include a first mounting hole <NUM>. The first mounting hole <NUM> may be a through hole that may be configured to receive a fastener <NUM>, such as a bolt, that may couple or mount the pin <NUM> to a control arm, such as the upper control arm <NUM>.

The second end portion <NUM> may be disposed opposite the first end portion <NUM>. The second end portion <NUM> may extend from a second end surface of the pin <NUM> that may be disposed opposite the first end surface. The second end portion <NUM> may be disposed outside of the upper hole <NUM> and may include a second mounting hole <NUM>. The second mounting hole <NUM> may be a through hole that may be configured to receive a fastener <NUM> that may couple or mount the pin <NUM> to the control arm. Accordingly, the pin <NUM> may not rotate with respect to the upper control arm <NUM> and may rotate with the upper control arm <NUM> about the pin axis <NUM> with respect to the knuckle carrier <NUM>.

The shoulder <NUM> may be axially positioned between the first end portion <NUM> and the second end portion <NUM>. For example, the shoulder <NUM> may be axially positioned between the first end portion <NUM> and the center portion <NUM>. The shoulder <NUM> may be partially or completely received in the upper hole <NUM>. The shoulder <NUM> may extend further from the pin axis <NUM> than the first end portion <NUM>, second end portion <NUM>, center portion <NUM>, the threaded portion <NUM>, or combinations thereof. The shoulder <NUM> may have an outer shoulder surface <NUM> that may face away from the pin axis <NUM> and may extend around the pin axis <NUM>. In at least one configuration, the outer shoulder surface <NUM> may be in outside circumference of the shoulder <NUM> and may be disposed at a substantially constant radial distance from the pin axis <NUM>. The shoulder <NUM> may also have a shoulder side surface <NUM> that may extend from the outer shoulder surface <NUM> to the center portion <NUM>.

The center portion <NUM> may be axially positioned between the shoulder <NUM> and the threaded portion <NUM>. The center portion <NUM> may be received in the upper hole <NUM>. The center portion may have an outside circumferential surface that may face away from the pin axis <NUM> and may extend from the shoulder <NUM> to or toward the threaded portion <NUM>. The outside circumferential surface may support the first bearing assembly <NUM> and the second bearing assembly <NUM> and may be disposed closer to the pin axis <NUM> or have a smaller diameter than the outer shoulder surface <NUM>.

The threaded portion <NUM> may be axially positioned between the center portion <NUM> and the second end portion <NUM>. As such, the shoulder <NUM>, the center portion <NUM>, and the threaded portion <NUM> may be axially positioned between the first mounting hole <NUM> and the second mounting hole <NUM>. The threaded portion <NUM> may be disposed inside the upper hole <NUM>, outside the upper hole <NUM>, or may be partially disposed in the upper hole <NUM>. In at least one configuration, the threaded portion <NUM> may be disposed closer to the pin axis <NUM> than the center portion <NUM> and may be disposed further from the pin axis <NUM> than the second end portion <NUM>.

The first bearing assembly <NUM> may rotatably support the pin <NUM>. The first bearing assembly <NUM> may be disposed in the upper hole <NUM> and may have any suitable configuration. For example, the first bearing assembly <NUM> may be configured as a roller bearing assembly that may include a plurality of rolling elements <NUM> that may be disposed between a first inner race <NUM> and a first outer race <NUM>.

The first inner race <NUM> may receive the pin <NUM>. For example, the first inner race <NUM> may extend around and may engage the center portion <NUM> of the pin <NUM>. In addition, the first inner race <NUM> engage or contact the shoulder side surface <NUM> of the shoulder <NUM> of the pin <NUM>. As such, the shoulder <NUM> may inhibit axial movement of the first inner race <NUM> away from the second bearing assembly <NUM>.

The first outer race <NUM> may extend around rolling elements <NUM> and the first inner race <NUM>. The first outer race <NUM> may engage the knuckle carrier <NUM>. For example, the first outer race <NUM> may be disposed on the first bearing support surface <NUM> and may engage or contact the first step surface <NUM> of the knuckle carrier <NUM>. As such, the first step surface <NUM> may inhibit axial movement of the first outer race <NUM> toward the second bearing assembly <NUM>.

The second bearing assembly <NUM> may also rotatably support the pin <NUM>. The second bearing assembly <NUM> may be disposed in the upper hole <NUM> and may have any suitable configuration. For example, the second bearing assembly <NUM> may be configured as a roller bearing assembly that may include a plurality of rolling elements <NUM> that may be disposed between a second inner race <NUM> and a second outer race <NUM>.

The second inner race <NUM> may receive the pin <NUM>. For example, the second inner race <NUM> may extend around and may engage the center portion <NUM> of the pin <NUM>. In addition, the second inner race <NUM> engage or contact the preload nut <NUM>.

The second outer race <NUM> may extend around rolling elements <NUM> and the second inner race <NUM>. The second outer race <NUM> may engage the knuckle carrier <NUM>. For example, the second outer race <NUM> may be disposed on the second bearing support surface <NUM> and may engage or contact the second step surface <NUM> of the knuckle carrier <NUM>. As such, the second step surface <NUM> may inhibit axial movement of the second outer race <NUM> toward the first outer race <NUM> of the first bearing assembly <NUM>. In addition, the intermediate portion <NUM> of the knuckle carrier <NUM> may extend from the first outer race <NUM> to the second outer race <NUM> and may help separate the first bearing assembly <NUM> from the second bearing assembly <NUM>.

The preload nut <NUM> may be configured to exert a preload force on the first bearing assembly <NUM>, the second bearing assembly <NUM>, or both. The preload nut <NUM> may receive the pin <NUM>. In at least one configuration, the preload nut <NUM> may include a first end surface <NUM>, a second end surface <NUM>, a hole <NUM>, a threaded region <NUM>, an outer surface <NUM>, and a flange <NUM>.

The first end surface <NUM> may face toward the second bearing assembly <NUM>. For example, the first end surface <NUM> may engage the second inner race <NUM> of the second bearing assembly <NUM>. In at least one configuration, first end surface <NUM> may be disposed in the upper hole <NUM> and may be disposed substantially perpendicular to the pin axis <NUM>.

The second end surface <NUM> may be disposed opposite the first end surface <NUM>. As such, the second end surface <NUM> may face away from the second bearing assembly <NUM>. The second end surface <NUM> may be disposed substantially perpendicular to the pin axis <NUM>. Optionally, the second end surface <NUM> may be disposed outside the upper hole <NUM>.

The hole <NUM> may extend from the first end surface <NUM> to the second end surface <NUM>. The hole <NUM> may receive the pin <NUM>.

The threaded region <NUM> may be disposed in the hole <NUM> and may extend between the first end surface <NUM> and the second end surface <NUM>. The threaded region <NUM> may include one or more threads that may made with the threaded portion <NUM> of the pin <NUM>.

The outer surface <NUM> may face away from the pin <NUM> and the hole <NUM>. In addition, the outer surface <NUM> may be spaced apart from the knuckle carrier <NUM>. The outer surface <NUM> may extend from the first end surface <NUM> to the flange <NUM>. In at least one configuration, the outer surface <NUM> or a portion thereof may be an outside circumferential surface of the preload nut <NUM>.

The flange <NUM> may be axially positioned between the outer surface <NUM> and the second end surface <NUM>. In addition, the flange <NUM> may be spaced apart from the knuckle carrier <NUM>. The flange <NUM> may extend outward with respect to the outer surface <NUM> or may extend further away from the pin axis <NUM> than the outer surface <NUM>. In at least one configuration, the flange <NUM> may include a plurality of flats or substantially planar faces that may facilitate engagement with a tool, such as a wrench. The flange <NUM> may be disposed partially or completely outside the upper hole <NUM>.

Tightening the preload nut <NUM> may exert a preload force the first bearing assembly <NUM> and the second bearing assembly <NUM>. For instance, tightening the preload nut <NUM> may actuate the pin <NUM> in an axial direction such that the shoulder <NUM> actuates the first inner race <NUM> toward the second bearing assembly <NUM> or to the right from the perspective shown in <FIG>. The first outer race <NUM> may be prevented from moving axially in the same direction by the intermediate portion <NUM> of the knuckle carrier <NUM>. As such, force may be exerted against the rolling elements <NUM> of the first bearing assembly <NUM> to provide a desired preload force and to inhibit skidding that may reduce bearing life. In addition, tightening the preload nut <NUM> may cause the preload nut <NUM> to exert force against the second inner race <NUM> in an axial direction that extends toward the first bearing assembly <NUM> or to the left from the perspective shown in <FIG>. The second outer race <NUM> may be prevented from moving axially in the same direction by the intermediate portion <NUM>. As such, force may be exerted against the rolling elements <NUM> of the second bearing assembly <NUM> to inhibit skidding and to provide a desired preload force.

The first seal <NUM> may inhibit contaminants from entering the end of the upper hole <NUM> that is disposed proximate the first bearing assembly <NUM>. The first seal <NUM> may extend between the pin <NUM> and the knuckle carrier <NUM>. In at least one configuration, the first seal <NUM> may extend from the first seal support surface <NUM> to the outer shoulder surface <NUM> of the shoulder <NUM>. As such, the first seal <NUM> may be at least partially disposed in the upper hole <NUM> and the shoulder <NUM> may be received in the first seal <NUM>. In addition, the first seal <NUM> may engage the first outer step surface <NUM> to inhibit axial movement of the first seal <NUM> toward the first bearing assembly <NUM>. The first seal <NUM> may be spaced apart from and may not engage the first bearing assembly <NUM>.

The second seal <NUM> may inhibit contaminants from entering the end of the upper hole <NUM> that is disposed proximate the second bearing assembly <NUM>. The second seal <NUM> may extend between the preload nut <NUM> and the knuckle carrier <NUM>. In at least one configuration, the second seal <NUM> may extend from the second seal support surface <NUM> to the outer surface <NUM> of the preload nut <NUM>. As such, the second seal <NUM> may be at least partially disposed in the upper hole <NUM> and the preload nut <NUM> may be received in the second seal <NUM>. In addition, the second seal <NUM> may engage the second outer step surface <NUM> to inhibit axial movement of the second seal <NUM> toward the second bearing assembly <NUM>. The second seal <NUM> may be spaced apart from and may not engage the second bearing assembly <NUM>.

Referring to <FIG>, an upper control arm <NUM> may extend from a lateral side of the frame <NUM> to a corresponding knuckle carrier <NUM>. An upper control arm <NUM> may be pivotally or rotatably mounted to the frame <NUM> in a manner that allows the steering knuckle <NUM>, knuckle carrier <NUM>, and a corresponding wheel end assembly <NUM> to move up and down while inhibiting forward and backward movement. For example, the upper control arm <NUM> may have a pair of arms that may be pivotally coupled to the frame <NUM> with a pivot mechanism. The pivot mechanism may have any suitable configuration. For example, the pivot mechanism may include a pivot pin about which the upper control arm <NUM> may rotate. The pivot pin may be fixedly coupled to the frame <NUM> in any suitable manner, such as with one or more fasteners like bolts. As is best shown in <FIG>, the arms may also cooperate to partially define an opening through which the shock absorber <NUM> may extend.

Referring to <FIG>, the lower control arm <NUM> may be disposed below the upper control arm <NUM>. A pair of lower control arms <NUM> may extend from opposing lateral sides of the frame <NUM> to a corresponding knuckle carrier <NUM>. A lower control arm <NUM> may be pivotally or rotatably mounted to the frame <NUM> in a manner that allows the steering knuckle <NUM>, knuckle carrier <NUM>, and a corresponding wheel end assembly <NUM> to move up and down while inhibiting forward and backward movement. For example, the lower control arm <NUM> may have a pair of arms that may be pivotally coupled to the frame <NUM> with a pivot mechanism. The pivot mechanism may have any suitable configuration as previously discussed.

Referring to <FIG>, the platform <NUM> is fixedly disposed on the knuckle carrier <NUM>. According to the invention, the platform <NUM> is fixedly disposed on the mounting stem <NUM>. In at least one configuration, the platform <NUM> may be completely located above the knuckle carrier <NUM>, the upper control arm <NUM>, or both. In at least one configuration, the platform <NUM> may have a disc portion <NUM> and has an arm <NUM>.

The disc portion <NUM> may facilitate mounting of the platform <NUM> to the knuckle carrier <NUM>. In addition, the disc portion <NUM> may support and facilitate mounting of the air spring <NUM> to the platform <NUM>. As is best shown in <FIG>, the disc portion <NUM> may be generally configured as a circular disk. Referring to <FIG> and <FIG>, the disc portion <NUM> may be mounted to the knuckle carrier <NUM> in any suitable manner. For instance, the disc portion <NUM> may have a first set of holes <NUM> that may receive fasteners <NUM>, such as screws, that may couple the disc portion <NUM> to the knuckle carrier <NUM>. In addition, the disc portion <NUM> may have a second set of holes <NUM> that may receive fasteners <NUM>, such as bolts, that may couple the air spring <NUM> to the platform <NUM>. The members of the second set of holes <NUM> may be disposed closer to the outside perimeter or outside circumference of the disc portion <NUM> than the first set of holes <NUM>.

The arm <NUM> is coupled to the stabilizer bar subassembly <NUM>. As is best shown in <FIG>, the arm <NUM> may extend along an arm axis <NUM>. The arm axis <NUM> may be substantially parallel to the first control arm axis. In addition, the arm <NUM> may extend toward the rear of the vehicle <NUM> or toward the bottom of <FIG> from the perspective shown in <FIG>. As such, the arm <NUM> may extend in a rearward longitudinal direction or a direction that extends longitudinally between the front and the rear of the vehicle <NUM> and toward the rear of the vehicle <NUM>. In addition, the arm <NUM> may be disposed further inboard or further away from the steering knuckle <NUM> than the first set of holes <NUM> and may extend tangentially from an inboard side or edge of the disc portion <NUM>.

Referring to Figures <NUM>-<NUM> and <FIG>, the air spring <NUM> and the shock absorber <NUM> may be provided to control and dampen movement of the suspension system <NUM>.

The air spring <NUM> may be disposed on a top surface of the platform <NUM>. As such, the air spring <NUM> may extend from the platform <NUM> upward to the frame <NUM>. The air spring <NUM> may have any suitable configuration. For instance, the air spring <NUM> may have a mounting plate, flexible bellows, and a piston. The mounting plate may be disposed at the top of the air spring <NUM> and may be fixedly mounted to the frame, such as with one or more fasteners. The flexible bellows may extend from the mounting plate to the piston. The flexible bellows may at least partially define a chamber within the air spring <NUM> that may receive the piston and an inflation gas. Inflation gas may be provided to the chamber or may be vented from the chamber to adjust the ride height and dampening characteristics of the suspension system. The piston may be at least partially received in the flexible bellows and may be fixedly mounted to the platform <NUM>.

The shock absorber <NUM>, which may also be referred to as a strut, may extend from the frame to the knuckle carrier <NUM>. For example, the shock absorber <NUM> may be pivotally mounted to the frame <NUM> at a first end and may be pivotally mounted to the first and second mounting tabs <NUM>, <NUM> of the shock absorber mount <NUM> at a second end with fasteners <NUM> such as bolts, which are best shown in <FIG>.

Referring to <FIG>, the wheel end assembly <NUM> may facilitate rotation a wheel that may support a tire. The wheel end assembly <NUM> may be part of a drive axle or a non-drive axle. A drive axle may receive torque from a power source, such as an internal combustion engine or electric motor. In a drive axle configuration, a shaft may transmit torque to the wheel end assembly <NUM> to rotate a wheel that may be mounted on the wheel end assembly <NUM>. For instance, the shaft may be operatively connected at a first end to a vehicle drivetrain component like a differential, gearbox, or motor and may extend through the steering knuckle <NUM> and may be coupled to the wheel end assembly <NUM> at a second end. Such a shaft may be omitted in a non-drive axle configuration. In at least one configuration, the wheel end assembly <NUM> may include a hub <NUM>.

The hub <NUM> may be rotatably disposed on the spindle <NUM> of the steering knuckle <NUM>. For example, one or more wheel bearings may be disposed on the spindle <NUM> and may rotatably support the hub <NUM>. The hub <NUM> may facilitate mounting of the wheel, such as with a plurality of mounting studs <NUM>. As such, the hub <NUM> and the wheel may rotate together about the second axis <NUM>. A tire may be disposed on the wheel that may engage a road or support surface.

Referring to <FIG> and <FIG>, the brake subsystem <NUM> may facilitate braking of the wheel to slow rotation of the hub <NUM> and an associated wheel about the second axis <NUM> of the wheel end assembly <NUM>. The brake subsystem <NUM> may have any suitable configuration. For instance, the brake subsystem <NUM> may be configured as a friction brake, such as a disc brake or a drum brake. In the configuration shown, the brake subsystem <NUM> is configured as a disc brake.

Referring to <FIG>, a portion of a steering subsystem <NUM> is shown. The steering subsystem <NUM> may steer or change the direction of travel of the vehicle. The steering subsystem <NUM> may include a linkage arrangement that may include a steering arm <NUM> and a tie rod <NUM>. The steering arm <NUM> may be is fixedly mounted to the steering knuckle <NUM>. The tie rod <NUM> may be pivotally coupled to an end of the steering arm <NUM> and may be operatively connected to a steering gear by one or more additional linkages. The steering gear may actuate the linkage arrangement to rotate the steering knuckle <NUM> about the first axis <NUM>. The steering gear may be disposed on the frame <NUM> or may be fixedly positioned with respect to the frame <NUM>.

The stabilizer bar subassembly <NUM> may help reduce body roll or side-to-side rolling of the vehicle <NUM>, such as may occur during cornering. The stabilizer bar operatively connects opposite knuckle carriers of the vehicle <NUM>. For example, the stabilizer bar subassembly <NUM> may be coupled to an arm <NUM> of the platform <NUM> that is disposed on the left side of the vehicle <NUM> and to a corresponding arm <NUM> of a platform <NUM> is disposed on a right side of the vehicle <NUM>. According to the invention, the stabilizer bar subassembly <NUM> is disposed above the upper control arm <NUM> and the knuckle carrier <NUM>. Moreover, the stabilizer bar subassembly <NUM> is spaced apart from and may not be coupled to the upper control arm <NUM> or the lower control arm <NUM>. According to the invention, the stabilizer bar subassembly includes a stabilizer bar and a drop link that extends from the arm to a first end of an intermediate link such that the drop link extends in an upward direction that extends away frmo the upper control arm. In at least one configuration, the stabilizer bar subassembly <NUM> may include a pair of drop links <NUM>, a pair of intermediate links <NUM>, and includes a stabilizer bar <NUM>. One drop link <NUM> extends from the arm <NUM> to a first end of an intermediate link <NUM>. A second end of the intermediate link <NUM> may be coupled to a first end of the stabilizer bar <NUM>. A mirror image arrangement of the drop link and intermediate link may be provided with an opposing wheel. For instance, another drop link <NUM> may extend from the arm <NUM> of a platform <NUM> that is provided with an opposing wheel to a first end of another intermediate link <NUM>, which in turn may extend to a second end of the stabilizer bar <NUM> that may be disposed opposite the first end. This drop link <NUM> extends in an upward direction that extends away from the upper control arm <NUM>. The intermediate links <NUM> may extend substantially horizontally and in a rearward direction. As such, the drop links <NUM> and intermediate links <NUM> may help position the stabilizer bar <NUM> above the wheels and control arms and may help provide ample ground clearance.

Claim 1:
A suspension system for a vehicle comprising:
an air spring (<NUM>);
a stabilizer bar subassembly (<NUM>);
a knuckle carrier (<NUM>) that has a mounting stem (<NUM>);
a steering knuckle (<NUM>) that is pivotally mounted to the knuckle carrier (<NUM>) along an axis of rotation (<NUM>);
an upper control arm (<NUM>) that is pivotally mounted to the knuckle carrier (<NUM>) along a first control arm axis (<NUM>); and
a platform (<NUM>) that is fixedly disposed on the mounting stem (<NUM>) and located above the upper control arm (<NUM>), wherein the platform (<NUM>) supports the air spring (<NUM>) and has an arm (<NUM>) that is coupled to the stabilizer bar subassembly (<NUM>), wherein the stabilizer bar subassembly (<NUM>) is disposed above the upper control arm (<NUM>) and the knuckle carrier (<NUM>) and includes a stabilizer bar (<NUM>), characterized in that the stabilizer bar subassembly (<NUM>) further includes a drop link (<NUM>) that extends from the arm (<NUM>) to a first end of an intermediate link (<NUM>) such that the drop link (<NUM>) extends in an upward direction that extends away from the upper control arm (<NUM>).