Abstract: A suspension bar assembly for an automotive vehicle includes a suspension bar having a bushing, a bushing retainer that exerts radially and axially compressive forces onto the bushing such that the bushing is in frictional engagement with the suspension bar, thereby preventing relative movement of the bushing and the suspension bar, and a mounting bracket that is adapted to connect the suspension bar to the automotive vehicle. A method of inducing a pre-load onto a bushing that supports a bar includes: providing a bar, placing a bushing onto the bar, placing a bushing retainer onto the bushing, and compressing the bushing axially and radially within the bushing retainer.

Abstract: A stabilizer bar assembly for an automotive vehicle includes a stabilizer bar, a bushing mounted to the stabilizer bar that has a first stiffness in a first radial plane, and a second stiffness in a second radial plane approximately perpendicular to the first radial plane, a bushing retainer in mechanically compressive engagement with the bushing such that the bushing is in frictional engagement with the stabilizer bar, thereby preventing relative movement of the bushing and the stabilizer bar, and a mounting bracket adapted to connect the stabilizer bar to the automotive vehicle.

Abstract: A spindle for use in an automobile chassis is provided. An aluminum knuckle with an axial through hole defined in its interior is provided along with a substantially cylindrical steel stem with an interlocking feature defined on one end. The interlocking feature has an extended flange with an outer diameter greater than the inner diameter of the through hole in the knuckle. The interlocking feature also has a frusto-conical section and at least a portion of the stem is welded to at least a portion of the through hole such that the interlocking feature is within the through hole.

Abstract: A suspension component for an automobile, such as a stabilizer bar, is provided and includes at least one localized portion having a strengthened outer surface. The localized portion is positioned at a location of highest stress along the suspension component. A method of forming the suspension component is also disclosed.

Abstract: An independent vehicle suspension includes a knuckle assembly supported by control arms or links. The knuckle assembly includes a forged, elongated steel spindle, one end of which includes a pair of axially-spaced radial flanges separated by a radially-enlarged shank portion. The knuckle assembly further includes an aluminum knuckle body defining at least one attachment point for the links. The knuckle assembly is formed by insert-casting the knuckle body about the shank portion of the spindle to thereby fully encapsulate the shank portion within, and at least partially encircle an axial portion of each spindle flange with, the as-cast knuckle body. A radial shoulder, for example, machined on the spindle's outboard end proximate to the outboard flange, axially supports the inner race of a bearing assembly, thereby advantageously reducing wheelend run-out. One or more peripheral flats on either spindle flange resists torsion, thereby allowing the machining of spindle surfaces after insert-casting.

Abstract: A suspension bar assembly for an automotive vehicle includes a suspension bar having a bushing, a bushing retainer that exerts radially and axially compressive forces onto the bushing such that the bushing is in frictional engagement with the suspension bar, thereby preventing relative movement of the bushing and the suspension bar, and a mounting bracket that is adapted to connect the suspension bar to the automotive vehicle. A method of inducing a pre-load onto a bushing that supports a bar includes: providing a bar, placing a bushing onto the bar, placing a bushing retainer onto the bushing, and compressing the bushing axially and radially within the bushing retainer.

Abstract: A stabilizer bar assembly for an automotive vehicle includes a stabilizer bar, a bushing mounted to the stabilizer bar that has a first stiffness in a first radial plane, and a second stiffness in a second radial plane approximately perpendicular to the first radial plane, a bushing retainer in mechanically compressive engagement with the bushing such that the bushing is in frictional engagement with the stabilizer bar, thereby preventing relative movement of the bushing and the stabilizer bar, and a mounting bracket adapted to connect the stabilizer bar to the automotive vehicle.

Abstract: A compression spring comprising a plurality of composite wave rings stacked and attached to one another in crest to crest configuration. Each of the wave rings has a plurality of alternating peaks and troughs wherein one peak and one adjacent trough define a wave having a wave height measured axially from the peak to the trough and the wave heights vary such that the compression spring provides a varying spring rate as the compression spring is compressed.

Abstract: A compression spring comprising a plurality of composite wave rings stacked and attached to one another in crest to crest configuration. Each of the wave rings has a plurality of alternating peaks and troughs wherein one peak and one adjacent trough define a wave having a wave height measured axially from the peak to the trough and the wave heights vary such that the compression spring provides a varying spring rate as the compression spring is compressed.

Abstract: A stabilizer bar assembly includes a stabilizer bar having a bushing, a bushing retainer in mechanical compressive engagement with the bushing, and a mounting bracket adapted to connect the stabilizer bar to an automotive vehicle. The bushing retainer can have a uniform outer diameter such that the bushing is compressed uniformly over the entire length of the bushing retainer, or, alternatively, the bushing retainer can have a stepped outer diameter such that the bushing is compressed differently within discreet sections along the length of the bushing retainer. A method of inducing a pre-load onto a bushing that supports a stabilizer bar includes: providing a stabilizer bar, placing a bushing onto the stabilizer bar, placing a bushing retainer, having an first outer diameter onto the bushing, and reducing the outer diameter of the bushing retainer to a second diameter that is smaller than the first diameter.

Abstract: A spindle for use in an automobile chassis is provided. An aluminum knuckle with an axial through hole defined in its interior is provided along with a substantially cylindrical steel stem with an interlocking feature defined on one end. The interlocking feature has an extended flange with an outer diameter greater than the inner diameter of the through hole in the knuckle. The interlocking feature also has a frusto-conical section and at least a portion of the stem is welded to at least a portion of the through hole such that the interlocking feature is within the through hole.