Torque Rod For Vehicle Suspension

Abstract

A fabricated torque rod including a rod having first and second ends, a first bushing hub welded to the first end of the rod and a second bushing hub welded to the second end of the rod; wherein the rod is a piece cut from a metal plate or sheet, wherein the first and second bushing hubs are made of cut tubing, wherein the first end of the rod has a radius that conforms to an outer surface of the first bushing hub and the second end of the rod has a radius that conforms to an outer surface of the second bushing hub, and wherein the first end of the rod is welded to the outer surface of the first bushing hub and the second end of the rod is welded to the outer surface of the second bushing hub.

What is claimed is: 
     
         1 . A fabricated torque rod for use in a vehicle suspension, comprising:
 a rod having a first end and an oppositely disposed second end;   a first bushing hub; and   a second bushing hub;   wherein the rod comprises a piece cut from a metal plate or sheet;   wherein the first bushing hub comprises cut tubing;   wherein the second bushing hub comprises cut tubing;   wherein the first end of the rod has a radius that conforms to an outer surface of the first bushing hub;   wherein the second end of the rod has a radius that conforms to an outer surface of the second bushing hub;   wherein the first end of the rod is welded to the outer surface of the first bushing hub; and   wherein the second end of the rod is welded to the outer surface of the second bushing hub.   
     
     
         2 . The fabricated torque rod of  claim 1 , wherein the first end of the rod includes a first finger that extends around at least a portion of the outer surface of the first bushing hub and the first finger is welded to the first bushing hub; and
 wherein the second end of the rod includes a first finger that extends around at least a portion of the outer surface of the second bushing hub and the first finger is welded to the second bushing hub.   
     
     
         3 . The fabricated torque rod of  claim 2 , wherein the first end of the rod includes a second finger that extends around at least a portion of the outer surface of the first bushing hub on a side of the first bushing hub opposite from the first finger, and the second finger is welded to the first bushing hub. 
     
     
         4 . The fabricated torque rod of  claim 3 , wherein the second end of the rod includes a second finger that extends around at least a portion of the outer surface of the second bushing hub on a side of the second bushing hub opposite from the first finger, and the second finger is welded to the second bushing hub. 
     
     
         5 . The fabricated torque rod of  claim 3 , wherein the first and second fingers of the first end of the rod completely encircle the first bushing hub. 
     
     
         6 . The fabricated torque rod of  claim 4 , wherein the first and second fingers of the first end of the rod completely encircle the first bushing hub, and wherein the first and second fingers of the second end of the rod completely encircle the second bushing hub. 
     
     
         7 . The fabricated torque rod of  claim 2 , wherein the rod, first finger of the first end of the rod and the first finger of the second end of the rod comprise a contiguous piece cut from the metal plate or sheet. 
     
     
         8 . The fabricated torque rod of  claim 7 , wherein a second finger is welded to the first end of the torque rod and a second finger is welded to the second end of the torque rod. 
     
     
         9 . The fabricated torque rod of  claim 4 , wherein the first and second fingers of the first end of the rod are welded to the first end of the rod, and wherein the first and second fingers of the second end of the rod are welded to the second end of the rod. 
     
     
         10 . The fabricated torque rod of  claim 4 , wherein a first mounting flange is welded to the second bushing hub and a second mounting flange is welded to the second bushing hub. 
     
     
         11 . The fabricated torque rod of  claim 3 , wherein a mounting bracket having a first mounting flange and a second mounting flange is welded to the second bushing hub. 
     
     
         12 . The fabricated torque rod of  claim 1 , wherein the first and second bushing hubs are cut from Electrically Resistance Welded tubing. 
     
     
         13 . The fabricated torque rod of  claim 1 , wherein the first and second bushing hubs are cut from seamless tubing. 
     
     
         14 . The fabricated torque rod of  claim 1 , wherein an outer surface of the first and second fingers of the first and second ends of the rod are flat. 
     
     
         15 . The fabricated torque rod of  claim 1 , wherein the first and second bushing hubs have a wall thickness of ⅜ths of an inch. 
     
     
         16 . The fabricated torque rod of  claim 1 , wherein the first and second bushing hubs have an inner diameter of 2.5 to 3 inches. 
     
     
         17 . The fabricated torque rod of  claim 1 , wherein the first and second bushing hubs comprise one of the group consisting of 1020 steel and 1026 steel. 
     
     
         18 . The fabricated torque rod of  claim 1 , wherein a central portion of the rod has been coined. 
     
     
         19 . The fabricated torque rod of  claim 1 , wherein the first and second bushing hubs are constructed of DOM tubing. 
     
     
         20 . The fabricated torque rod of  claim 1 , wherein the first bushing hub has a first end and a second end disposed opposite the first end, and the first and second ends of the first bushing hub have a reduced wall thickness relative to a wall thickness of a central portion of the first bushing hub positioned between the first and second ends of the first bushing hub, and wherein the first and second ends of the first bushing hub are adapted to be curled over opposite ends of a first bushing assembly positioned within the first bushing hub to retain the first bushing assembly within the first bushing hub. 
     
     
         21 . The fabricated torque rod of  claim 20 , wherein the second bushing hub has a first end and a second end disposed opposite the first end, and the first and second ends of the second bushing hub have a reduced wall thickness relative to a wall thickness of a central portion of the second bushing hub positioned between the first and second ends of the second bushing hub, and wherein the first and second ends of the second bushing hub are adapted to be curled over opposite ends of a second bushing assembly positioned within the second bushing hub to retain the second bushing assembly within the second bushing hub. 
     
     
         22 . The fabricated torque rod of  claim 20 , wherein the first and second ends of the first bushing hub have a wall thickness that is ¼ to ½ of the wall thickness of the central portion of the first bushing hub. 
     
     
         23 . The fabricated torque rod of  claim 21 , wherein the first and second ends of the second bushing hub have a wall thickness that is ¼ to ½ of the wall thickness of the central portion of the second bushing hub. 
     
     
         24 . A method of fabricating a torque rod including the steps of:
 cutting a rod out of a piece of metal plate or sheet that is at least ¼ inch thick;   cutting a first piece of tubing to form a first bushing hub;   cutting a second piece of tubing to form a second bushing hub;   welding a first end of the rod to the first bushing hub; and   welding a second end of the rod to the second bushing hub.   
     
     
         25 . The method of  claim 24 , wherein the step of cutting a rod out of a piece of metal plate or sheet comprises one of plasma, laser, or waterjet cutting the piece of metal plate or sheet. 
     
     
         26 . The method of  claim 24 , wherein prior to the step of welding the first end of the rod to the first bushing hub, first and second ends of the tubing used to form the first bushing hub are machined to provide a reduced wall thickness on the first and second ends of the first bushing hub. 
     
     
         27 . The method of  claim 26 , further including the steps of inserting a first bushing assembly into the first bushing hub, and curling the first and second ends of the first bushing hub over opposite ends of the first bushing assembly to retain the first bushing assembly within the first bushing hub. 
     
     
         28 . The method of  claim 27 , wherein prior to the step of welding the second end of the rod to the second bushing hub, first and second ends of the tubing used to form the second bushing hub are machined to provide a reduced wall thickness on the first and second ends of the first bushing hub. 
     
     
         29 . The method of  claim 28 , further including the steps of inserting a second bushing assembly into the second bushing hub, and curling the first and second ends of the second bushing hub over opposite ends of the second bushing assembly to retain the second bushing assembly within the second bushing hub. 
     
     
         30 . The method of  claim 24 , wherein the step of cutting a rod out of a piece of metal plate or sheet includes cutting the metal plate or sheet so that a first finger extends from the first end of the rod and a second finger extends from the second end of the rod. 
     
     
         31 . The method of  claim 30 , further including the step of welding a second finger to the first end of the rod and the step of welding a second finger to the second end of the rod. 
     
     
         32 . The method of  claim 24 , further including the step of coining a central portion of the rod. 
     
     
         33 . The method of  claim 32 , wherein the coining step occurs before any of the welding steps. 
     
     
         34 . The method of  claim 32 , wherein a cross-section of the central portion of the rod has a first side having a curved surface and an oppositely disposed second side having a curved surface. 
     
     
         35 . The fabricated torque rod of  claim 18 , wherein a cross-section of the central portion of the rod has a first side having a curved surface and an oppositely disposed second side having a curved surface.