Stabilizer bar assembly for vehicle suspension system

Abstract

A suspension system having a stabilizer bar assembly with a stabilizer bar structure, an intermediate bushing and a resilient bushing. The stabilizer bar structure includes a center section to which the intermediate bushing is coupled. The resilient bushing is mounted on the intermediate bushing. The intermediate bushing limits relative axial movement of the resilient bushing in along the center section in a first direction and a second direction opposite the first direction. A method for forming a stabilizer bar assembly is also provided.

1 . A stabilizer bar assembly comprising:
 a bar having a center section and first and second end sections disposed on opposite sides of said center section;   a locating collar coupled to said center section at a first location;   a first bushing disposed over said locating collar such that said locating collar limits bi-directional axial movement of said first bushing relative to said center section; and   a second bushing disposed for axially sliding movement on said center section relative to said first bushing toward a second location.   
   
   
       2 . The stabilizer bar assembly of  claim 1  wherein said locating collar is fixed to said center section at said first location and has first and second thrust surfaces, and wherein said first bushing surrounds said locating collar such that said first thrust surface inhibits axial movement of said first bushing in a first direction along said center section and said second thrust surface inhibits axial movement of said first bushing in a second direction along said center section. 
   
   
       3 . The stabilizer bar assembly of  claim 2  wherein said first bushing encloses said locating collar and has an inner surface engaging an outer surface of said center section. 
   
   
       4 . The stabilizer bar assembly of  claim 2  wherein said locating collar is molded onto said center section of said bar. 
   
   
       5 . The stabilizer bar assembly of  claim 1  wherein said locating collar extends outwardly from a tubular member that is coupled to said center section at said first position, and wherein said first bushing surrounds said tubular member. 
   
   
       6 . The stabilizer bar assembly of  claim 5  wherein said locating collar has first and second thrust surfaces such that said first thrust surface inhibits axial movement of said first bushing relative to said center section in a first direction and said second thrust surface inhibits axial movement of said first bushing in a second direction relative to said center section. 
   
   
       7 . The stabilizer bar assembly of  claim 5  further including a second locating collar extending outwardly from said tubular member and which is laterally spaced relative to said first locating collar, and wherein said first bushing is disposed between said first and second locating collars such that said first locating collar inhibits axial movement of said first bushing relative to said center section in a first direction and said second locating collar inhibits axial movement of said first bushing relative to said center section in a second directions. 
   
   
       8 . The stabilizer bar assembly of  claim 7  wherein said first and second locating collars are formed at opposite ends of said tubular member, and wherein a first end surface of said first bushing engages said first locating collar and a second end surface of said first bushing engages said second locating collar. 
   
   
       9 . The stabilizer bar assembly of  claim 1  wherein said first bushing has a center aperture, and wherein at least one of said center aperture, said locating collar and said center section is formed with a non-circular cross section such that said first bushing acts as a torsion spring to resist rotation of said center section. 
   
   
       10 . A stabilizer bar assembly, comprising:
 a bar having a center section and first and second end sections extending from opposite ends of said center section;   an intermediate bushing coupled to said center section at a first location and having a tubular member surrounding a portion of said center section and a locating collar extending outwardly from said tubular member;   a first bushing disposed over said tubular member such that said locating collar limits bi-directional axial movement of said first bushing relative to said center section; and   a second bushing disposed for axial sliding movement on said center section toward a second location.   
   
   
       11 . The stabilizer bar assembly of  claim 10  wherein said locating collar has first and second thrust surfaces, and wherein said first bushing surrounds said locating collar such that said first thrust surface inhibits axial movement of said first bushing in a first direction and said second thrust surface inhibits axial movement of said first bushing in a second direction. 
   
   
       12 . The stabilizer bar assembly of  claim 11  wherein said first bushing encloses said locating collar and has an inner surface engaging an outer surface of said tubular member. 
   
   
       13 . The stabilizer bar assembly of  claim 10  wherein said intermediate bushing further includes a second locating collar extending outwardly from said tubular member and which is laterally spaced relative to said first locating collar. 
   
   
       14 . The stabilizer bar assembly of  claim 13  wherein said first bushing is disposed between said first and second locating collars such that said first locating collar inhibits axial movement of said first bushing in a first direction and said second locating collar inhibits axial movement of said first bushing in a second direction. 
   
   
       15 . The stabilizer bar assembly of  claim 14  wherein said first and second locating collars are formed at opposite ends of said tubular member, and wherein a first end surface of said first bushing engages said first locating collar and a second end surface of said first bushing engages said second locating collar. 
   
   
       16 . The stabilizer bar assembly of  claim 13  wherein said first bushing surrounds and encloses at least one of said first and second locating collars. 
   
   
       17 . The stabilizer bar assembly of  claim 10  wherein said intermediate bushing is molded onto said center section at said first location. 
   
   
       18 . The stabilizer bar assembly of  claim 10  wherein said first bushing has a center aperture, and wherein at least one of said center aperture, said locating collar, said tubular member and said center section is formed with a non-circular cross section such that said first bushing acts as a torsion spring to resist rotation of said center section. 
   
   
       19 . A stabilizer bar assembly comprising:
 a bar having a center section and first and second end sections disposed on opposite sides of said center section;   a locator coupled to said center section at a first location;   a first bushing disposed over said locator such that said locator limits bi-directional axial movement of said first bushing relative to said center section; and   a second bushing disposed for axially sliding movement on said center section relative to said first bushing toward a second location.   
   
   
       20 . The stabilizer bar assembly of  claim 19  wherein said locator is a locating collar. 
   
   
       21 . The stabilizer bar assembly of  claim 20  wherein said locating collar is fixed to said center section at said first location and has first and second thrust surfaces, and wherein said first bushing surrounds said locating collar such that said first thrust surface inhibits axial movement of said first bushing in a first direction along said center section and said second thrust surface inhibits axial movement of said first bushing in a second direction along said center section. 
   
   
       22 . The stabilizer bar assembly of  claim 21  wherein said first bushing encloses said locating collar and has an inner surface engaging an outer surface of said center section. 
   
   
       23 . The stabilizer bar assembly of  claim 20  wherein said locating collar extends outwardly from a tubular member that is coupled to said center section at said first position, and wherein said first bushing surrounds said tubular member. 
   
   
       24 . The stabilizer bar assembly of  claim 23  wherein said locating collar has first and second thrust surfaces such that said first thrust surface inhibits axial movement of said first bushing relative to said center section in a first direction and said second thrust surface inhibits axial movement of said first bushing in a second direction relative to said center section. 
   
   
       25 . The stabilizer bar assembly of  claim 23  further including a second locating collar extending outwardly from said tubular member and which is laterally spaced relative to said first locating collar, and wherein said first bushing is disposed between said first and second locating collars such that said first locating collar inhibits axial movement of said first bushing relative to said center section in a first direction and said second locating collar inhibits axial movement of said first bushing relative to said center section in a second directions. 
   
   
       26 . The stabilizer bar assembly of  claim 25  wherein said first and second locating collars are formed at opposite ends of said tubular member, and wherein a first end surface of said first bushing engages said first locating collar and a second end surface of said first bushing engages said second locating collar.