Abstract: A leading or trailing arm vehicle suspension system comprised of a fabricated vehicle axle and a fully integrated beam casting providing bending stiffness to control axle windup and longitudinal stiffness to control axle position is disclosed. The beam casting is attached to the vehicle axle with a thru-bolt connection. The beam casting includes rack and pinion mounting attachment holes and also includes other built-in features providing efficient transfer of loads into the vehicle axle.

Abstract: A vehicle leaf spring suspension having a low spring rate is disclosed. The suspension has an axle seat secured to a vehicle axle. The leaf spring is clamped at its spring seat area to the axle seat at the clamp group mounting surface of the axle seat and with certain of the disclosed axle seats, can be clamped such that the spring seat area is asymmetrically positioned with respect to the vehicle axle centerline. Also, an active clamp group arrangement can be used to utilize the entire physical length of the leaf spring.

Abstract: A lightweight heavy duty bushing assembly for use in a vehicle suspension system and being low cost and having a high assembly tolerance is disclosed. A metal bar pin is press fit into a bushing formed from a metal sleeve bonded to an elastomeric housing. The metal sleeve is deformable such that exact tolerances of the metal sleeve and the bar pin are not required. The metal bar pin has extended ends with a hole in each end for attachment of the metal bar pin to vehicle suspension components, mounting brackets, or to the vehicle frame.

Abstract: A clamp assembly of a vehicle leaf spring suspension is disclosed. The clamp assembly has an axle bracket secured to a vehicle axle and a top cap secured to the axle bracket by mechanical fasteners to define an axle seat. The axle bracket and top cap may include interlocking keys and keyways to cooperate with the mechanical fasteners in transmitting the load from the vehicle axle. A spring seat of the leaf spring is received within the axle seat and is tapered. The tapered spring seat, when combined with a deformable liner in the axle seat, effectively eliminates the inactive portion of the leaf spring to increase the effective length of the spring and minimize the spring rate.

Abstract: An elastomeric spring suspension is described for supporting a longitudinally extending vehicle frame rail above first and second axles forming a tandem axle configuration. The suspension includes a frame hanger assembly mounted to the vehicle frame rail. The frame hanger assembly has two full spring modules, each of which includes two elastomeric shear springs, an elastomeric progressive spring rate load cushion having a pyramidal shape with a flattened top surface and a spring mount for mounting the springs. A saddle assembly is connected to the spring mount, and an equalizing beam is connected to the saddle assembly and further connected to the axles. The spring rate for the suspension increases almost linearly as a function of sprung load, resembling a pneumatic suspension. Accordingly, the suspension exhibits excellent ride quality, without sacrificing roll stability.

Abstract: A fabricated vehicle axle is provided with a single piece main body having an inverted U-shaped configuration. The ends of the main body are curved upwardly to define a pair of gooseneck portions. A first king pin fixture having a king pin bore is secured to one of the gooseneck portions, while a second king pin fixture having a king pin bore is secured to the other gooseneck portion. A bottom plate is secured to the main body and has ends extending beyond the gooseneck portions to provide seats for the king pin fixtures.

Abstract: A clamp assembly of a vehicle leaf spring suspension is disclosed. The clamp assembly has an axle bracket secured to a vehicle axle and a top cap secured to the axle bracket by mechanical fasteners to define an axle seat. The axle bracket and top cap may include interlocking keys and keyways to cooperate with the mechanical fasteners in transmitting the load from the vehicle axle. A spring seat of the leaf spring is received within the axle seat and is tapered. The tapered spring seat, when combined with a deformable liner in the axle seat, effectively eliminates the inactive portion of the leaf spring to increase the effective length of the spring and minimize the spring rate.

Abstract: A leading or trailing arm vehicle suspension system comprised of a fabricated vehicle axle and a fully integrated beam casting providing bending stiffness to control axle windup and longitudinal stiffness to control axle position is disclosed. The beam casting is attached to the vehicle axle with a thru-bolt connection. The beam casting includes rack and pinion mounting attachment holes and also includes other built-in features providing efficient transfer of loads into the vehicle axle.

Abstract: A leading or trailing arm vehicle suspension system comprised of a fabricated vehicle axle and an arm assembly. The arm assembly includes an axle bracket attached to the axle and a leading or trailing arm attached to the axle bracket. The arm provides bending stiffness to control axle windup and longitudinal stiffness to control axle position is disclosed. The axle bracket is attached to the vehicle axle with a through-bolt connection. The axle bracket or the arm includes rack and pinion mounting attachment holes and also includes other built-in features providing efficient transfer of loads into the vehicle axle.

Abstract: A clamp assembly of a vehicle leaf spring suspension is disclosed. The clamp assembly has an axle bracket secured to a vehicle axle and a top cap secured to the axle bracket by mechanical fasteners to define an axle seat. The axle bracket and top cap may include interlocking keys and keyways to cooperate with the mechanical fasteners in transmitting the load from the vehicle axle. A spring seat of the leaf spring is received within the axle seat and is tapered. The tapered spring seat, when combined with a deformable liner in the axle seat, effectively eliminates the inactive portion of the leaf spring to increase the effective length of the spring and minimize the spring rate.

Abstract: A leading or trailing arm vehicle suspension system comprised of a fabricated vehicle axle and a fully integrated beam casting providing bending stiffness to control axle windup and longitudinal stiffness to control axle position is disclosed. The beam casting is attached to the vehicle axle with a thru-bolt connection. The beam casting includes rack and pinion mounting attachment holes and also includes other built-in features providing efficient transfer of loads into the vehicle axle.

Abstract: A vehicle leaf spring suspension having a low spring rate is disclosed. The suspension has an axle seat secured to a vehicle axle. The leaf spring is clamped at its spring seat area to the axle seat at the clamp group mounting surface of the axle seat and with certain of the disclosed axle seats, can be clamped such that the spring seat area is asymmetrically positioned with respect to the vehicle axle centerline. Also, an active clamp group arrangement can be used to utilize the entire physical length of the leaf spring.

Abstract: A clamp assembly of a vehicle leaf spring suspension is disclosed. The clamp assembly has an axle bracket secured to a vehicle axle and a top cap secured to the axle bracket by mechanical fasteners to define an axle seat. The axle bracket and top cap may include interlocking keys and keyways to cooperate with the mechanical fasteners in transmitting the load from the vehicle axle. A spring seat of the leaf spring is received within the axle seat and is tapered. The tapered spring seat, when combined with a deformable liner in the axle seat, effectively eliminates the inactive portion of the leaf spring to increase the effective length of the spring and minimize the spring rate.

Abstract: A fabricated vehicle axle is provided with a single piece main body having an inverted U-shaped configuration. The ends of the main body are curved upwardly to define a pair of gooseneck portions. A first king pin fixture having a king pin bore is secured to one of the gooseneck portions, while a second king pin fixture having a king pin bore is secured to the other gooseneck portion. A bottom plate is secured to the main body and has ends extending beyond the gooseneck portions to provide seats for the king pin fixtures.

Abstract: An elastomeric spring suspension is described for supporting a longitudinally extending vehicle frame rail above first and second axles forming a tandem axle configuration. The suspension includes a frame hanger assembly mounted to the vehicle frame rail The frame hanger assembly has two full spring modules, each of which includes two elastomeric shear springs, an elastomeric progressive spring rate load cushion having a pyramidal shape with a flattened top surface and a spring mount for mounting the springs. A saddle assembly is connected to the spring mount, and an equalizing beam is connected to the saddle assembly and further connected to the axles. The spring rate for the suspension increases almost linearly as a function of sprung load, resembling a pneumatic suspension. Accordingly, the suspension exhibits excellent ride quality, without sacrificing roll stability.

Abstract: A lightweight heavy duty bushing assembly for use in a vehicle suspension system and being low cost and having a high assembly tolerance is disclosed. A metal bar pin is press fit into a bushing formed from a metal sleeve bonded to an elastomeric housing. The metal sleeve is deformable such that exact tolerances of the metal sleeve and the bar pin are not required. The metal bar pin has extended ends with a hole in each end for attachment of the metal bar pin to vehicle suspension components, mounting brackets, or to the vehicle frame.

Abstract: A non-torque reactive air suspension exhibiting excellent roll stability characteristics is shown to include frame hangers mounted to frame rails extending longitudinally on opposite sides of a vehicle. Longitudinally extending beams are connected to the frame hangers at one end and extend parallel to the frame rails. At their other ends, the beams are joined by a crossbrace extending laterally across the vehicle centerline. In a central portion thereof, the beams have an axle pivot bore to which an axle clamp assembly is connected, the axle clamp assembly clamping a drive axle housing for the vehicle. The axle pivot bore is generally aligned with the drive axle. A control rod assembly is connected to suspension or frame components. Together with the beams, the control rod assembly forms a parallelogram configuration wherein the beams form the lower linkages of that configuration and the control rods included within the control rod assembly form the upper linkages of that configuration.

Abstract: The invention is directed to vehicle suspension systems and components thereof including attachment devices for mounting an axle alignment and/or load reacting mechanism to an axle. Disclosed herein are axle towers used for connecting a torque box to an axle. The axle tower of the present invention can include one or more features to absorb and disperse loads to the axle. The axle tower has a more contoured or curved edge on the side plate that experiences a compressive force than a similar edge on the side plate that experiences a tensile force. Furthermore, the axle tower has appendages that extend out from the side plates providing a large footprint on the axle housing. At least one of the appendages extending from the side plate experiencing a compressive force has a curved or radiused corner. Also, the axle towers include an inner plate having an off-centered slot where the troque box connects.

Abstract: A leading or trailing arm vehicle suspension system comprised of a fabricated vehicle axle and an arm assembly. The arm assembly includes an axle bracket attached to the axle and a leading or trailing arm attached to the axle bracket. The arm provides bending stiffness to control axle windup and longitudinal stiffness to control axle position is disclosed. The axle bracket is attached to the vehicle axle with a through-bolt connection. The axle bracket or the arm includes rack and pinion mounting attachment holes and also includes other built-in features providing efficient transfer of loads into the vehicle axle.

Abstract: A fabricated vehicle axle is shown to include a main body having an inverted U-shaped configuration. The fabricated vehicle axle further includes a continuous bottom plate welded to the main body. The fabricated axle also includes a first king pin top plate having a reversed curved fork portion welded to the main body at one end thereof. Similarly, the fabricated vehicle axle includes a second king pin top plate having a reversed curved fork portion welded to the main body at an opposite end thereof. Still further, the fabricated vehicle axle includes a first gooseneck part welded to the first king pin top plate and the first end of the bottom plate. Similarly, the fabricated vehicle axle includes a second gooseneck part welded to the second king pin top plate and the second end of the bottom plate. REEXAMINATION RESULTS The questions raised in reexamination request 90/007,703, filed Sep.