Stabilizer bar

Abstract

A method of making a stabilizer bar 10 from a tubular blank to which a bonding agent 32 is applied to the inside surface 76 of opposite ends of the tube. The tube may be provided with tubular inserts 80 that are also provided with a bonding agent. The bonding agent may be an adhesive that is cured and then the bonding agent is placed in an oven to melt the bonding agent. The ends are swaged to shape and the ends of the tube are trimmed and pierced to form a fastener eyelet 38 in each end. Optionally, the stabilizer bar may then be heated for hot working to form the bends along the length of the bar. After forming to shape, the stabilizer bar may be quenched and annealed.

1 . A stabilizer bar for a vehicle comprising: 
 a tubular member having two ends, the tubular member having an opening extending between the two ends;    each of the ends having a bonding agent applied on their inner diameters, the ends each having flattened portions that are bonded together to form a seal; and    each of the ends having a hole for receiving a fastener.    
     
     
         2 . The stabilizer bar of  claim 1  wherein the bonding agent comprises a powdered metal comprising powdered nickel and boron.  
     
     
         3 . The stabilizer bar of  claim 2  wherein the bonding agent bonds to the ends of the tubular member and the boron facilitates bonding the ends of the tubular member.  
     
     
         4 . The stabilizer bar of  claim 2  wherein the bonding agent is an epoxy.  
     
     
         5 . The stabilizer bar of  claim 1  further comprising a pair of tubular inserts being disposed with one tubular insert secured to each end of the tubular member.  
     
     
         6 . The stabilizer bar of  claim 5  wherein the bonding agent is applied to an interior and an exterior surface of the tubular inserts.  
     
     
         7 . The stabilizer bar of  claim 1  wherein the bonding agent is electroless nickel.  
     
     
         8 . The stabilizer bar of  claim 1  wherein the bonding agent is epoxy.  
     
     
         9 . A stabilizer bar made in accordance with a method comprising the steps of: 
 providing a tubular member having an inner diameter and two open ends;    applying a bonding agent to the two ends of the tubular member;    curing the bonding agent;    heating the tubular member and the bonding agent to soften the bonding agent;    forming two ends of the tubular member to form two flattened ends while the bonding agent is heated to at least a temperature wherein the bonding agent is in a malleable state; and    swaging each of the two ends to form an eyelet for a fastener.    
     
     
         10 . The stabilizer bar made according to the method of  claim 9  wherein the bonding agent is a mixture of powdered nickel and boron.  
     
     
         11 . The stabilizer bar made according to the method of  claim 9  wherein the step of applying the bonding agent is performed by a step selected from the group consisting of brushing on the mixture, spraying, injecting and placing capsules.  
     
     
         12 . The stabilizer bar made according to the method of  claim 9  wherein the bonding agent comprises electroless nickel applied in an immersion bath with an electrolytic charge.  
     
     
         13 . The stabilizer bar made according to the method of  claim 9  wherein the bonding agent comprises an epoxy resin.  
     
     
         14 . The stabilizer bar made according to the method of  claim 13  wherein the epoxy is initially contained in a capsule that is placed in one of the ends of the tubular member and then melted to release the epoxy into the tube.  
     
     
         15 . The stabilizer bar made according to the method of  claim 9  wherein the step of forming the two ends to form two flattened ends further comprises bonding the two ends together so that the bonding agent seals the two ends of the tubular member.  
     
     
         16 . The stabilizer bar made according to the method of  claim 9  further comprising the steps of: 
 reheating the tubular member;    bending the tubular member along its length while heated;    quenching the tubular member in a quenching fluid; and    annealing the tubular member.    
     
     
         17 . The stabilizer bar made according to the method of  claim 16  wherein during the step of quenching the tubular member, the quenching fluid being oil, the bonding agent seals the two ends of the tubular member to prevent the quenching fluid from being drawn into the tubular member.  
     
     
         18 . A stabilizer bar made in accordance with a method comprising the steps of: 
 providing a tubular member having an inner diameter and two open ends;    applying a sealing agent to the two ends of the tubular member;    form the two ends of the tubular member to form two flattened ends; and    forming a hole in each of the two ends.    
     
     
         19 . The stabilizer bar of  claim 18  wherein the sealing application step comprises providing a sealing agent having about 1-5% Si, 0.2-2% B; 0.5-4.5% P; and a balance of Ni.  
     
     
         20 . The stabilizer bar of  claim 19  wherein the sealing agent comprises about 3.7% Si; 1% B; 2%P; a balance of Ni.