Magna International Inc.

Volvo Group North America, LLC

Volvo Truck Corporation

Automotive Components Holdings, LLC

Gregory Paul Kiselis

Seetarama S Kotagiri

Timothy Walter Skszek

Frank A Horton

Dalip K Matharoo

Gianfranco Gabbianelli

Michael Alwyn Brown

Mark Francis Werner

Warren Edward Young

Jeffrey Jay Mellis

Pascal P Charest

Ryan Robert Warpup

Eric deNijs

Jeffrey W Nichols

Daniel Sulisz

DeWayne Dale Egle

Ying Zhang

Neil Alan Wasylewski

Arthur Nalson Fowler

Paul Eugene Beshears, Jr

Erryn Leigh Ashmore

Erryn Leigh Langlois

Sampath Rengarajan

Andrew Slupecki

David Robert Helebrant

Adrian N Oprea

An automotive component including a composite casting is provided. The composite casting includes a steel member and an end cap fastened to an end portion of the steel member. A cast coupling member is cast about the end portion of the steel member including the end cap, thereby positively and rigidly securing the cast coupling member to the steel member. The automotive component can comprise an engine cradle, a control arm, an instrument panel support structure, a bumper assembly, or a twist axle. The cast coupling member is typically formed by casting-in-place aluminum about the end cap and the end portion of the steel member. The steel member is typically a tubular member, and the end cap typically includes a flange designed to provide a mechanical interlock surface with the cast coupling member. For example, the flange can have a polygonal shape, an outwardly extending member, or notches.

Controlled pressure casting

The present invention relates to a vehicle provided with a sprung mass, including a vehicle frame, at least one axle provided with first and second ends, and a suspension system provided with a mechanical springs and leveling springs. The mechanical springs connect the axle ends to the frame and are provided with a spring rate in a rebound direction that is greater than or substantially equal to a spring rate in a jounce direction. The leveling springs are configured to support the sprung mass at one or more sprung mass load points, whereby the first and second mechanical springs may become substantially unloaded by the sprung mass of the vehicle at the one or more sprung mass load points.

Vehicle suspension system and method for increasing the roll rate of a vehicle

A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Hybrid component

The present invention relates to a vehicle and a method for improving the roll characteristics of a vehicle. The vehicle includes an axle, a sprung mass, a first control arm, a second control arm, a third control arm, a first pivotable joint, a second pivotable joint, a third pivotable joint, and a fourth pivotable joint. The torsional stiffness of the first control arm, the second control arm, the first pivotable joint, the second pivotable joint, the third pivotable joint, and the fourth pivotable joint are substantially equal to or greater than the torsional stiffness of the axle, whereby the axle bends and twists during a sprung mass roll event in order to limit an amount of roll.

Vehicle with a four bar link suspension system provided with improved roll characteristics

A method of assembling a frame and suspension module includes determining locations of first and second suspension member supports on the frame. Target positions of first and second connections between the frame and third and fourth suspension members are defined based on the locations of the first and second suspension member supports. Target positions of third and fourth connections between a fifth suspension member and the first and second suspension members are defined based on the locations and the target positions of the first and second connections. The first and second suspension members are connected to the frame at the locations. The third and fourth suspension members are connected to the frame at the first and second target positions. The fifth suspension member is connected to the first and second suspension members at the third and fourth target positions.

Method to produce suspension module and frame that reduces need for final alignment

A suspension arrangement for interconnecting a frame and an axle in a vehicle includes a control arm having an upper beam and a lower beam, each beam having a first end and a second end, the first end of each beam being pivotally connectable to a vehicle frame at a common pivot point, and the second end of each beam being connected to a bushing arrangement mountable to the vehicle axle, the bushing arrangement having an upper portion connected to the upper beam and a lower portion connected to the lower beam.

Twist beam suspension with dual beam control arm

A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to densify the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

A suspension arrangement for interconnecting a frame and an axle in a vehicle includes a control arm having a first beam and a second beam in parallel, spaced relation, each beam having a first end with a single arm and a second end with an upper arm and a lower arm to define a Y-shape, the first end being pivotally connectable to a vehicle frame, and the second end being connectable to a vehicle axle disposed between the upper and lower arms, and a bushing arrangement mountable to the vehicle axle, the bushing arrangement having an upper portion connecting between the upper arms of the first beam and second beam and a lower portion connecting between the lower arms of the first beam and second beam.

Twist beam suspension with Y-beam control arm

A suspension for a motor vehicle having a hollow suspension member including first and second spaced apart sidewalls and a pivot pin. In the preferred embodiment, the pivot pin is a locking assembly that includes a first retainer partially insertable through a first window formed in the first sidewall and a second retainer partially insertable through a second window formed in the second side wall. The first retainer engages the second retainer to present a pivot that receives a pivot arm between the sidewalls.

Suspension link with integral pivot assembly

An assembly including a control arm and a steering knuckle, one of the control arm and the steering knuckle having a first end with a ball, the other of the control arm and the steering knuckle having a socket that includes a bearing structure formed so as to surround a portion of the ball to securely fasten the ball to the socket. The control arm has a bayonette configuration to receive a first node and a second node is cast directly onto the control arm.

Control arm and knuckle assembly

A motor vehicle frame includes a pair of longitudinal frame members. A cross member is provided to maintain the frame members in a spaced apart condition. The cross member has a first end configured to mount to a first one of the longitudinal frame members and a second end configured to engage a steering gear housing. The second end sandwiches steering gear housing as the second end is fastened to a second one of the frame members.

Integral cross member with steering gear joint

A low insertion force snap together automotive coupler for the suspension of a vehicle includes a spherical bearing insert having a first end, a second end, a pocket adapted to engage a ball stud that is integrally formed onto a suspension component, and an axially extending annular flange. The coupler further includes a receiver adapted to receive the spherical bearing insert after the spherical bearing insert has been placed to a ball stud and to engage the flange to secure the spherical bearing insert within the receiver. The pocket within the spherical bearing insert is shaped such that an axial force tending to pull the ball stud out of the pocket will result in a radial force exerted upon the flange, thereby causing additional force to keep the flange engaged within the receiver.

Growing community of inventors

Oak Ridge, NC, United States of America

Gregory Paul Kiselis