Two-piece vertical control arm bushing

Abstract

A bushing, for use with a control arm, has first and second mating segments that can be mated and assembled to form a central portion to be received within a circular opening in the control arm and the central portion has an outer diameter corresponding to the diameter of the circular opening. Each segment includes a cap or head portion having a diameter dimensioned to abut against one of the surfaces of the control arm and has a central bore. A bushing sleeve has a length equal to a axial length of the assembled bushing and an outer diameter incrementally greater than the diameter of the central bore so that the sleeve can be press fit within the bore to immobilize the segments when they are in contact with the control arm and become resistant to separation.

Claims

1. A bushing, for use with a control arm having upper and lower surfaces and a circular opening defining a vertical axis and a diameter D.sub.c, comprises (a) first and second mating segments defining an axis when mated and assembled to form a portion to be received within the circular opening and having an outer diameter substantially corresponding to the diameter D.sub.c, each segment including a cap or head portion associated with each of said segments and having a diameter greater than D.sub.c and dimensioned to abut against one of the upper and lower surfaces of the control arm and having a central bore having a predetermined diameter; and (b) a bushing sleeve having a length substantially equal to a fully mated bushing along said vertical axis and an outer diameter greater than said predetermined diameter of said central bore to allow said bushing sleeve to be inserted through said central bore in a press fit relationship in order to maintain said mating segments in assembled condition, said two segments of the control arm bushing being suitable to be inserted into said circular opening of the control arm from opposite sides of the control arm and coaxially aligned prior to being mated, said bushing sleeve being inserted through said central bore after said segments have been mated to substantially immobilize said first and second segments when they are in contact with the control arm and prevented from undesirably separating by moving in opposite directions along said axis.

2. The bushing as defined in claim 1, wherein said first segment is a female segment having an annular portion defining an outer diameter D.sub.o and a cylindrical inner chamber C having an inner diameter D.sub.i.

3. The bushing as defined in claim 2, wherein said second segment is a male segment having an annular portion defining an outer diameter d.sub.o greater than D.sub.i to provide a press fit when said segments are mated.

4. The bushing as defined in claim 3, said inner chamber C has an axial length or height h that is greater than an axial length or height of said annular portion of said first female segment, said inner chamber C axially extending into said cap or head portion associated with said first female segment.

5. The bushing as defined in claim 1, wherein said cap or head portions are integrally formed with associated segments.

6. The bushing as defined in claim 1, wherein said cap or head portions are formed with tapered or beveled surfaces at radically outer surfaces that do not contact the control arm when the bushing is assembled on the control arm.

7. The bushing as defined in claim 1, wherein said segments are made of rubber.

8. The bushing as defined in claim 1, wherein said bushing sleeve is provided with chamfers or bevels at opposing axial ends.

9. The bushing as defined in claim 1, wherein said bushing sleeve is made of steel.

10. A control arm comprises a member having upper and lower surfaces and a circular opening defining a vertical axis and a diameter D.sub.c; first and second mating segments defining an axis when mated and assembled to form a portion to be received within said circular opening, said first segment comprising a female segment having an outer diameter substantially corresponding to the diameter D.sub.c each segment including a cap or head portion having a diameter greater than D.sub.c and dimensioned to abut against one of said upper and lower surfaces of the control arm, said second segment comprising a male segment having a central bore having a predetermined diameter; a bushing sleeve having a length substantially equal to a fully mated bushing along said vertical axis and an outer diameter greater than said predetermined diameter of said central bore to allow said bushing sleeve to be inserted through said central bore in a press fit relationship in order to maintain said mating segments in assembled condition, said two segments being suitable to be inserted into said circular opening of the control arm from opposite sides of the control arm and coaxially aligned prior to being mated, said bushing sleeve being inserted through said central bore after said first and second segments have been mated to substantially immobilize said first and second segments when they are in contact with the control arm and prevented from undesirably separating by moving in opposite directions along said axis.

11. The control arm as defined in claim 10, wherein said female segment has an annular portion defining an outer diameter D.sub.o and a cylindrical inner chamber C having an inner diameter D.sub.i.

12. The control arm as defined in claim 11, wherein said male segment has an annular portion defining an outer diameter d.sub.o greater than D.sub.i to provide a press fit when said segments are mated.

13. The control arm as defined in claim 12, said inner chamber C has an axial length or height h that is greater than an axial length or height of said annular portion of said first female segment, said inner chamber C axially extending into said cap or head portion associated with said first female segment.

14. The control arm as defined in claim 10, wherein said cap or head portions are integrally formed with associated segments.

15. The control arm as defined in claim 10, wherein said cap or head portions are formed with tapered or beveled surfaces at radically outer surfaces that do not contact the control arm when the bushing is assembled on a control arm.

16. The control arm as defined in claim 10, wherein said segments are made of rubber.

17. The control arm as defined in claim 10, wherein said bushing sleeve is provided with chambers or bevels at opposing axial ends.

18. The control arm as defined in claim 10, wherein said bushing sleeve is made of steel.

19. A method of assembling a bushing, for use with a control arm having upper and lower surfaces and a circular opening defining a vertical axis and a diameter D.sub.c, first and second mateable segments defining an axis when mated and assembled to form a portion to be received within the circular opening, said first segment comprising a female segment having an outer diameter substantially corresponding to the diameter D.sub.c, each segment including a cap or head portion associated with each of said segments and having a diameter greater than D.sub.c and dimensioned to abut against one of said upper and lower surfaces of the control arm and having a central bore having a predetermined diameter; a bushing sleeve wherein said second segment comprises a male segment having a length substantially equal to a fully mated bushing along said vertical axis and an outer diameter greater than said predetermined diameter of said central bore to allow said bushing sleeve to be inserted through said central bore in a press fit relationship in order to maintain said mating segments in assembled condition, the method comprising the steps of inserting the two mateable segments through the circular opening from opposite sides of the control arm and mating said segments to position said caps or heads of said segments into contact with the control arm; and inserting said bushing sleeve through said central bore to substantially immobilize said first and second segments when they are in contact with the control arm and prevented from undesirably separating by moving in opposite directions along said axis.

20. The method as defined in claim 19, wherein axially inward pressure is applied to mate said segments and to insert said bushing sleeve through said central bore to lock said segments relative to each other by providing press-fits therebetween.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other aspects, features and advantages of the present invention will be more apparent from the following description when taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is a perspective image of a prior art control arm assembly illustrating both forward or front bushing having a generally horizontal axis and a rear bushing having a generally vertical axis.

(3) FIG. 2 is an exploded prospective view of a two-piece vertical control arm bushing in accordance with the present invention aligned in positions prior to being mated and fully assembled;

(4) FIG. 3 is a side elevational view of the female control arm bushing segment shown in FIG. 2;

(5) FIG. 4 is a top plan view of the bushing segment shown in FIG. 3;

(6) FIG. 5 is a enlarged fragmented detail of the region A shown in FIG. 3;

(7) FIG. 6 is a side elevational view of the lower male control arm bushing segment shown in FIG. 2;

(8) FIG. 7 is a top plan view of the bushing segment shown in FIG. 6;

(9) FIG. 8 is an enlarged fragmented detail of the region B shown in FIG. 6.

(10) FIG. 9 is a side elevational view of a bushing sleeve used to secure the coaxially aligned and assembled segments shown in FIGS. 3-8 and for providing a central channel through which a bolt or pin can pass for attachment of the control arm to a component of a suspension system of a vehicle;

(11) FIG. 10 is a side elevational view of the bushing sleeve shown in FIG. 9; and

(12) FIG. 11 is a perspective view of a control arm with the two-piece vertical control arm bushing in accordance with the invention showing the upper and lower bushing segments aligned and ready to be assembled and secured to the control arm.

DETAILED DESCRIPTION

(13) Referring now specifically to the figures, in which identical or similar parts designated by the same reference numerals throughout, and first referring to FIG. 1, a prior art control arm is generally designated by the reference numeral 10.

(14) The control arm assembly 10 is generally T-shaped as viewed in FIG. 1, having free end portions 12, 14 and 16. A ball joint assembly 18 is shown mounted on or supported by the portion 12 that includes an upwardly projecting stem 20 commonly used to secure the control arm assembly 10 to a suspension component of a vehicle.

(15) Provided at the portion 14 is a cylindrical front or forward tubular member 22 that defines a generally horizontal axis A.sub.H and houses a front bushing 24 that is received and supported by the cylindrical front or forward tubular member 22. The axis of the front bushing 24 is generally coextensive with the horizontal axis A.sub.H.

(16) The other end portion 16 forms a rear or back end 26 having upper and lower surfaces, as shown, and a circular opening 28 that defines a substantially vertical axis A.sub.V. Housed within and supported by the rear or back end 26 is a vertical rear bushing 30 that defines an axis that is coextensive with the vertical axis A.sub.V of the circular opening 28.

(17) During normal operation of the vehicle, the control arm portion 12, that carries the ball joint assembly 18, moves upwardly and downwardly generally along directions represented by the arrow 32. It will be appreciated that as the portion 12 moves up and down more extensively than the vertical movements of the portions 14, 16 the associated bushings 24 and 30 will be exposed to stresses including compressions and stretching. Since the movements of the front or forward portion 14 will be essentially about the horizontal axis H the front bushing 24 may be somewhat stressed but much less so than the rear vertical bushing 30. It is clear that rocking or pivoting movements of the control arm portion 16 while the central portion of the rear bushing 30 remains substantially vertical this will cause significant stresses and flexing of the rubber material of which the rear bushing is formed. While some efforts have been made to prevent premature deterioration of the rear bushing 30 due to such constant stresses, the bushing 30 is still exposed to significant stresses that cause the material to break down and deteriorate. Shown in FIG. 1 are slits or openings 34 as one proposed solution designed to reduce the amount of stresses applied to the rubber material when the portion 16 rocks from side to side, as viewed in FIG. 1, while the central part of the bushing 30 remains substantially vertical. Therefore, it is normally not a question of whether the rear bushings will ultimately deteriorate and fail but when or how quickly this will occur. Replacing the bushing 30 when it fails with a similar bushing will extend the life of the control arm assembly but the replacement bushing will also, in time, deteriorate and fail. Each time that a bushing, including an OEM bushing, fails it must be removed from the opening 28 and replaced by a new bushing. However, these bushings are press fit under significant compression forces and replacement of a failed bushing and replacement with a new bushing is not always simple and, frequently, if not always, requires special tools such as high power presses. This increases the time and labor charges for the owner of the vehicle.

(18) Referring to FIG. 2, a new vertical control arm bushing in accordance with the invention is shown and designated by the reference numeral 36. The bushing 36, as viewed in FIG. 2, includes an upper female segment 38. However, it will be appreciated that relative positional designations are not critical and the female segment 38 can also be positioned below the control arm and, therefore, be the lower segment.

(19) Referring to FIGS. 3-5, the female segment 38 includes an annular portion 40 that has an outside diameter D.sub.o and a chamber C with an inner diameter D.sub.i (FIG. 3). Provided at one end of the annular portion 40 is a head or cap portion 42 that has an outer diameter D.sub.t and a cylindrical opening or bore 44, the segment 38 having an overall height H (FIG. 3). The head or cap portion 42 includes an inclined surface 46. The chamber C with internal diameter D.sub.i somewhat extends into the head or cap portion 42, as shown in FIGS. 3 and 5, that provides an overall axial length or height for the inner chamber C of h (FIG. 3).

(20) Referring to FIGS. 6-8, the lower male segment 48 also has an annular portion 50 that has an outer diameter d.sub.o and an internal diameter d.sub.i as viewed in FIGS. 6 and 7. The male segment 48 also includes a head or cap portion 52 with an outer diameter d.sub.t and a cylindrical opening, channel or bore 54, and also formed with an inclined surface 56.

(21) Referring to FIGS. 9 and 10 a bushing or sleeve insert 58 is in the shape of a tubular member preferably provided with chamfered edges at both axial ends thereof. The bushing or sleeve 58 has an external diameter d and an internal diameter d′.

(22) It will be noted from the dimensions of the two segments 38 and 48 that the outer diameter d.sub.o of the segment 48 is substantially equal to the diameter d.sub.i of the upper segment 38. When coaxially aligned with the circular opening 28 on opposite sides of the portion 16 to be aligned coaxially with the vertical axis A.sub.V the annular portion 50 can be inserted into or received within the annular portion 40 of the upper segment 38 substantially the full axial height h of the interior cavity or chamber C. The axial length or height of the chamber C in the upper portion is slightly greater than the axial length h′ so that the entire annular portion 50 can be received within the interior cavity or chamber C of the upper segment with maximum penetration to insure minimum spacing between the heads or caps 42, 52 and reliable contact of the heads or caps with the control arm. This can be achieved with simple shop tools readily available in a shop or service station including a clamp, hammer or the like.

(23) Once the upper and lower segments are fully mated the bushing sleeve 58 is inserted into the cylindrical opening or bore 54. The outer diameter d of the sleeve 58 is selected to be somewhat greater than the inside diameter of the bores or channels 44 and 54 so that a press fit is created when the sleeve is inserted into the two segments. The axial 1 length of the sleeve 58 is selected to be equal to the axial length or height H of the segment 38 and the axial thickness of the head or cap 52 of the segment. In the example shown, the axial length or height H of the upper segment 38 is equal to H or 1.770″ (FIG. 3). Once fully mated, the annular portion 50 is fully received within the cavity or chamber C of the upper segment 38. The head or cap portions 42, 52 abut against the opposing surfaces of the control arm portion 16. The length of the sleeve 58 is, therefore, selected to be 2.47″ which is the sum of the height H or 1.770″ of the segment 38 and the axial thickness of the head or cap portion 52, shown to be 0.7″, for a total of 2.47″. The chamfered axial ends of the bushing sleeve 58 facilitate insertion of the sleeve without damage to the internal surface of the segments 38, 48.

(24) It will be evident that the same two-piece bushing construction can be used in connection with numerous size and style control arms by selecting suitable outer diameters D.sub.o of the annular portion 40 to be compatible with the circular or cylindrical openings 28 in the control arm and by selecting the diameter d′ to accommodate the different bolts or pins that extend through the bushing for attachment to the suspension components.

(25) The upper or female and the lower male segments can be made from any suitable material commonly used for manufacturing bushings, such as rubber, or different formulations thereof, and the bushing sleeve 58 is typically formed of steel. The diameters of the cap portions 42, 52 are selected to provide annular surfaces adequate to abut against the upper and lower surfaces of the control arm. In the illustrated example, with D.sub.t equal to 3.475″ and the outer diameter D.sub.o equal to 2.913″ and the head or cap portion 42 has a diameter equal to 3.475″, so that the annular dimension of the overhang or portion that abuts the surface of the control arm portion 16 is approximately equal 0.562″. This number is not critical and may be modified to suit a particular control arm.

(26) It will be evident to those skilled in the art that the two-piece vertical control arm bushing in accordance with the present invention provides a simple, inexpensive, easy-to-install vertical control arm bushing that can be installed with tools conventionally found in service stations and without the need of heavy duty presses.

(27) While the invention has been shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents.