Robust, low mass stabilizer bar link assembly

Abstract

An end link adapted to interconnect a stabilizer bar and a suspension member within a vehicular suspension system includes a housing having a first socket, a second socket and a body interconnecting the first and second sockets. The end link also includes a first joint assembly pivotally interconnecting the first socket and the stabilizer bar and a second joint assembly pivotally interconnecting the second socket and the suspension member The first socket includes a net-shaped cavity to receive the first joint assembly.

What is claimed is:  
     
         1 . An end link adapted to interconnect a stabilizer bar and a suspension member within a vehicular suspension system, the end link comprising: 
 a housing having a first socket, a second socket and a body interconnecting said first and second sockets;    a first joint assembly pivotally interconnecting said first socket and the stabilizer bar;    a second joint assembly pivotally interconnecting said second socket and the suspension member, said first socket including a net-shaped cavity to receive said first joint assembly.    
     
     
         2 . The end link of  claim 1  wherein said first joint assembly includes a ball stud having a ball segment and a shank segment, said first joint assembly further including a support mechanism for pivotally supporting said ball segment within said first socket.  
     
     
         3 . The end link of  claim 2  wherein said shank segment is coupled to said stabilizer bar.  
     
     
         4 . The end link of  claim 3  wherein said net-shaped cavity includes a first bore having a first size and a second bore having a larger size, said support mechanism including a lower bearing positioned within said first bore and an upper bearing positioned within said second bore.  
     
     
         5 . The end link of  claim 4  wherein said lower bearing is press fit within said first bore.  
     
     
         6 . The end link of  claim 5  wherein said upper bearing has an outer surface spaced apart from an inner wall of said second bore.  
     
     
         7 . The end link of  claim 6  wherein said upper bearing includes a plurality of fingers biasedly engaged with said ball segment.  
     
     
         8 . The end link of  claim 7  wherein said first joint assembly includes an end cap positioned within a third bore of said net-shaped cavity, said first socket having a portion thereof deformed to retain said end cap within said third bore.  
     
     
         9 . The end link of  claim 1  wherein said housing is cast from an aluminum alloy containing magnesium in the range of .0.19 to .0.29 percent.  
     
     
         10 . The end link of  claim 9  wherein said housing exhibits elongation greater than eight percent under load.  
     
     
         11 . A suspension system for a motor vehicle comprising: 
 a stabilizer bar;    a suspension member;    an end link interconnecting said stabilizer bar and said suspension member, said end link including a housing having first and second net-shaped cavities, said end link further including a first joint assembly positioned in said first cavity to interconnect said stabilizer bar and said end link and a second joint assembly positioned in said second cavity to interconnect said suspension member and said end link.    
     
     
         12 . The suspension system of  claim 11  wherein said housing includes a generally cylindrical body having a first socket integrally formed at one end and a second socket integrally formed at the other end, said first socket defining said first net-shaped cavity and said second socket defining said second net-shaped cavity.  
     
     
         13 . The end link of  claim 12  wherein said first joint assembly includes a ball stud having a ball segment and a shank segment, said first joint assembly further including a support mechanism for pivotally supporting said ball segment within said first socket.  
     
     
         14 . The end link of  claim 13  wherein said shank segment is coupled to said stabilizer bar.  
     
     
         15 . The end link of  claim 14  wherein said net-shaped cavity includes a first bore having a first size and a second bore having a larger size, said support mechanism including a lower bearing positioned within said first bore and an upper bearing positioned within said second bore.  
     
     
         16 . The end link of  claim 15  wherein said upper bearing includes a plurality of fingers biasedly engaged with said ball segment.  
     
     
         17 . The end link of  claim 11  wherein said housing is cast from an aluminum alloy containing magnesium in the range of .0.19 to .0.29 percent.  
     
     
         18 . The end link of  claim 10  wherein said housing exhibits elongation greater than eight percent under load.  
     
     
         19 . A method of constructing an end link for a vehicle suspension, the method comprising: 
 die casting a housing having a first socket, a second socket and a body interconnecting said first and second sockets;    positioning a first joint assembly within said first socket wherein said first socket is in an as-cast condition;    positioning a second joint assembly within said second socket wherein said second socket is in an as-cast condition; and    retaining said first and second joints within said first and second sockets.    
     
     
         20 . The method of constructing an end link of  claim 19  wherein the step of retaining said first joint includes deforming a portion of said first socket to resist withdrawal of said first joint from said first socket.  
     
     
         21 . The method of constructing an end link of claim  20  wherein the step of die casting includes positioning a parting line proximate said portion to be deformed.