Abstract: A method of manufacturing a ball joint includes arranging a ball in a bore of a housing, and enclosing an end of the bore. Plastic is injected into a space between the housing and the ball to form a bearing that has a bearing surface that engages the ball. The bearing shrinks to form a recess in the bearing surface so that the recess can be filled with a grease.

Abstract: A ball joint includes a stud extending from a ball. A housing has a bore that receives the ball. The housing has an interior surface facing the ball that includes a groove. A plastic bearing is arranged between the ball and the housing. The plastic bearing has first and second sides opposite one another. The first side has a spherical surface engaging the ball. The second side has a protrusion opposite the spherical surface that is received in and fills the groove and a recess in the spherical surface opposite the protrusion.

Abstract: A method of manufacturing a ball joint includes arranging a ball in a bore of a housing, and enclosing an end of the bore. Plastic is injected into a space between the housing and the ball to form a bearing that has a bearing surface that engages the ball. The bearing shrinks to form a recess in the bearing surface so that the recess can be filled with a grease.

Abstract: A ball joint includes a stud extending from a ball. A housing has a bore that receives the ball. The housing has an interior surface facing the ball that includes a groove. A plastic bearing is arranged between the ball and the housing. The plastic bearing has first and second sides opposite one another. The first side has a spherical surface engaging the ball. The second side has a protrusion opposite the spherical surface that is received in and fills the groove and a recess in the spherical surface opposite the protrusion.

Abstract: A vehicle suspension system (55) is configured so as to contain all of the suspension motion control elements completely within the volume of the road wheel (100) while remotely locating the energy storage device (45) and damping device (42). An upright (60) comprises the spindle (61), brake caliper (105), and structure to hold a main strut shaft (70) parallel to a secondary strut shaft (67). The suspension's motion is controlled by the shafts which slide relative to the sprung part of the vehicle (1). The main strut shaft (70) includes a pumping piston (73). The fluid (91) displaced by the pumping piston (73) flows through a hydraulic connection (47) to a remote suspension module (40) mounted to the sprung part of the vehicle. The remote suspension module (40) hydraulically transmits the wheel motion to the remote energy storage device (45) and damping device (42).

Abstract: A structural element comprising a vehicle suspension control arm is constructed from a complex, single piece, sheet metal stamped component formed from a material of uniform thickness. The stamping is configured with the correct plan view shape and formed into an I-beam cross-section comprising a central web portion and two flange portions. The central web portion is configured as a single material thickness and the flange portions comprise upstanding and downstanding closed sections with a continuous double returned segment. The open ends of the sheet metal terminate at or near the central web portion and are welded to the web portion, and in an alternative embodiment also to the continuous double returned segment, to create a favorable structural I-beam section with flange portions twice the thickness of the web portion.

Abstract: A structural element comprising a vehicle suspension control arm is constructed from a complex, single piece, sheet metal stamped component formed from a material of uniform thickness. The stamping is configured with the correct plan view shape and formed into an I-beam cross-section comprising a central web portion and two flange portions. The central web portion is configured as a single material thickness and the flange portions comprise upstanding and downstanding closed sections with a continuous double returned segment. The open ends of the sheet metal terminate at or near the central web portion and are welded to the web portion, and in an alternative embodiment also to the continuous double returned segment, to create a favorable structural I-beam section with flange portions twice the thickness of the web portion.

Abstract: A vehicle suspension system (55) is configured so as to contain all of the suspension motion control elements completely within the volume of the road wheel (100) while remotely locating the energy storage device (45) and damping device (42). An upright (60) comprises the spindle (61), brake caliper (105), and structure to hold a main strut shaft (70) parallel to a secondary strut shaft (67). The suspension's motion is controlled by the shafts which slide relative to the sprung part of the vehicle (1). The main strut shaft (70) includes a pumping piston (73). The fluid (91) displaced by the pumping piston (73) flows through a hydraulic connection (47) to a remote suspension module (40) mounted to the sprung part of the vehicle. The remote suspension module (40) hydraulically transmits the wheel motion to the remote energy storage device (45) and damping device (42).