CROSS-REFERENCE TO RELATED APPLICATION

[0001] This PCT application claims the benefit of U.S. Patent Application Serial

No. 14/580,572 filed December 23, 2014 entitled "Ball Joint Assembly For A Control Arm" which claims priority to U.S. Provisional Patent Application Serial No. 61/947,760 filed March 4, 2014 entitled "Bushing Assembly", the entire disclosures of the applications being considered part of the disclosure of this application and hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention is related generally to bushing assemblies and more particularly to metal bushing assemblies having a stud and a housing which is rotatable relative to the stud.

2. Related Art

[0003] Many automotive vehicles today employ suspension systems commonly known as MacPherson strut systems or double-wishbone systems. Such systems typically include a lower control arm (also referred to as an A-arm) which pivots relative to the vehicle's frame to allow a wheel and tire to move upwardly and downwardly relative to the frame during cornering or in response to encountering an object, such as a pot hole in the road.

[0004] A lower control arm 10 for a Macpherson strut type of suspension system is generally shown in Figure 1. The lower control arm 10 includes a ball joint 11 for connection with a steering knuckle (not shown) of a hub assembly and a pair of bushings 12, 13 for guiding the pivoting movement of the lower control arm 10 relative to the vehicle's frame (not shown). One of the bushings is a horizontal bushing 12 which is configured to pivot relative to the vehicle frame about longitudinally extending bolt (not shown). The other bushing 13 is a vertical bushing which is configured to pivot relative to the vehicle frame about a vertically extending bolt (not shown).

[0005] Referring now to Figures 2A-C, an conventional vertical bushing 13 is generally shown. As best shown in Figure 2C, the conventional vertical bushing 13 has an outer metallic sleeve 14, which is press fit into an opening in the lower control arm 10

(shown in Figure 1), a rubber cushion 15 and an inner metallic sleeve 16. The rubber cushion 15 extends radially between and interconnects the outer and inner metallic sleeves 14, 16. In operation, the inner metallic sleeve 16 pivots or twists relative to the outer metallic sleeve 14 during movement of the vehicle suspension, such as when the vehicle encounters a pot hole in the road. The rubber cushion 15 deforms elastically to allow the pivoting movement between these sleeves 14, 16 and absorbs/deforms due to a radial load. As such, during operation of the vehicle, the rubber cushion 15 is exposed to both a radial load and a twisting load motion. Exposure to the radial load and twisting motion leads to deterioration in the rubber cushion 15, thereby reducing the life of the vertical bushing 13.

SUMMARY OF THE INVENTION

[0006] One aspect of the invention provides for an improved ball joint assembly for allowing rotation of a control arm relative to a vehicle frame. The ball joint assembly includes a housing which is adapted for receipt within an opening of the control arm. The ball joint assembly further includes a bearing which has an inner surface that extends between open first and second ends and which presents a curved bearing surface that surrounds a generally spherically-shaped cavity. A stud is provided which has an outer surface with a generally ball- shaped portion that has at least two curved surfaces and at least two recessed surfaces. The bearing further includes a passage with a pair of slots that extend from one of the open ends of the bearing to the spherically-shaped cavity. The generally ball-shaped portion of the stud is insertable into the spherically- shaped cavity of the bearing by aligning the curved surfaces of the stud with the slots of the passage. The stud is rotatable while the ball-shaped portion of the stud is positioned within the spherically-shaped cavity of the bearing to establish slidable contact between the curved surfaces of the stud and the curved bearing surface of the bearing to allow pivoting of the stud relative to the bearing.

[0007] The improved ball joint assembly exhibits reduced wear and thus has an improved operating life as compared to the vertical bushing assemblies that are typically found in such control arms. Additionally, the ball joint assembly can be manufactured at low cost and can be sold as an aftermarket part as a replacement for worn bushings.

[0008] Another aspect of the present invention provides for a method of making a ball joint assembly. The method includes the step of preparing a housing and a bearing. The bearing has a curved bearing surface that surrounds a generally spherically shaped cavity and has a passage with two slots that extend from an end of the bearing to the spherically shaped cavity. The method proceeds with the step of preparing a stud that includes a generally ball-shaped portion that has at least two curved surfaces and at least two recessed surfaces. The method continues with the step of aligning the curved surfaces of the ball-shaped portion of the stud with the slots of the passage of the bearing. The method proceeds with the step of guiding the ball shaped portion of the stud into the spherically shaped cavity of the bearing. The method continues with the step of guiding the ball shaped portion of the stud into the spherically shaped cavity of the bearing. The method proceeds with the step of rotating the stud relative to the bearing to establish slidable contact between the curved surfaces of the ball-shaped portion with the bearing surface of the bearing to allow pivoting of the stud relative to the bearing. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features and advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0010] Figure 1 is a perspective view of one known control arm assembly;

[0011] Figure 2A is a front elevation view of an exemplary vertical bushing from the control arm of Figure 1 ;

[0012] Figure 2B is a top elevation view of the vertical bushing of Figure 2A;

[0013] Figure 2C is a cross-sectional view of the vertical bushing of Figures 2A and

2B and taken along Line C-C of Figure 2B;

[0014] Figure 3 is a perspective view of an exemplary embodiment of an improved control arm assembly;

[0015] Figure 4 is a cross-sectional view of the control arm assembly of Figure 3 and connected with a vehicle frame;

[0016] Figure 5 is another cross-sectional view of the control arm assembly of

Figure 3 connected with a vehicle frame and in a different rotational position than Figure 4;

[0017] Figure 6 is yet another cross-sectional view of the control arm assembly of

Figure 3 connected with a vehicle frame and in a different rotational position than Figures 4 and 5;

[0018] Figure 7 is a cross-sectional and exploded view of an exemplary embodiment of an improved ball joint assembly of the control arm of Figure 3;

[0019] Figure 8 is a cross-sectional view of the ball joint assembly of Figure 7;

[0020] Figure 9 is a front elevation view of an exemplary embodiment of a stud of the ball joint assembly of Figure 7; [0021] Figure 10 is a top elevation view of the stud of Figure 9;

[0022] Figure 11 is a cross-sectional view of the stud of Figure 9 and taken along

Line 11-11 of Figure 10;

[0023] Figure 12 is a perspective view of the stud of Figure 9;

[0024] Figure 13 is a cross-sectional view of a housing of the ball joint assembly of

Figure 7;

[0025] Figure 14 is another cross-sectional view of the housing of the ball joint assembly of Figure 7 and taken from a different perspective than Figure 13;

[0026] Figure 15 is a top elevation view of the housing of Figure 13; and

[0027] Figure 16 is a perspective view of the housing of Figure 13.

DESCRIPTION OF THE ENABLING EMBODIMENT

[0028] Referring to Figures 3, an exemplary embodiment of a control arm assembly

20 for a vehicle suspension system is generally shown. The control arm assembly 20 includes a body 22 and a ball socket assembly 24 for attachment with a steering knuckle (not shown) of a vehicle. The control arm assembly 20 further includes a ball joint assembly 26 and a horizontal bushing 28 which are configured to join the control arm body 22 with a vehicle frame 30 (shown in Figures 6-8). As shown in Figures 6-8, the ball joint assembly 26 allows the control arm body 22 to pivot relative to the vehicle frame 30 during operation of the vehicle, for example, in response to a wheel on the vehicle encountering an obstacle such as a pothole or in response to the vehicle rolling while cornering at high speeds. Figure 5 shows the control arm body 22 in one pivoting position, and Figure 6 shows the control arm body 22 in another pivoting position. The ball joint assembly 26 includes a stud 32 which is fixed to the vehicle frame 30 with a fastener and a housing 34 which is engaged with the control arm body 22 and which is pivotable relative to the stud 32. In the exemplary embodiment, the fastener which fixes the stud 32 with the vehicle frame 30 is a bolt 36. However, any suitable type of fastener or connecting means may be employed.

[0029] As shown in Figure 4, the housing 34 of the exemplary embodiment has an exterior surface 38 which extends along an axis A and is shaped and sized to be press-fit into an opening of the control arm body 22. One axial end of the exterior surface 38 includes a radially outwardly extending flange 40. During installation of the ball joint assembly 26 into the control arm, the flange 40 defines a stopping point to ensure that the ball joint assembly 26 is properly installed in the opening of the control arm body 22. The housing 34 is preferably made of one integral piece of metal, such as steel.

[0030] The ball joint assembly 26 further includes a bearing 42 which establishes the pivoting relationship between the housing 34 and the stud 32. In the exemplary embodiment, the bearing 42 and the housing 34 are formed as one integral piece of metal. However, it should be appreciated that the bearing 42 and the housing 34 could alternately be constructed as separate elements which are formed separately and are subsequently joined together.

[0031] As shown in Figures 13 and 14, the bearing 42 has an inner surface which extends axially between opposite open first and second ends. A portion of the inner surface defines a curved bearing surface 44, which is curved with a generally constant diameter to present a generally spherically-shaped cavity (hereinafter referred to as the "spherical cavity 48")· As such, the curved bearing surface 44 is generally semi-spherically shaped or curved.

[0032] Referring back to Figure 4, in the exemplary embodiment, the stud 32 is formed of one integral piece of material and extends through the bearing 42 past the opposite open ends. The stud 32 has a through passage 50 for receiving the bolt 36 to attach the stud 32 with the vehicle frame 30. As shown in Figures 9-12, the stud 32 has a generally ball-shaped portion (hereinafter referred to as the "ball portion 52") and a pair of end portions 54. The ball portion 52 of the stud 32 has a pair of curved surfaces 55 and a pair of recessed surfaces 56. The curved surfaces 44 are generally semi- spherical in shape in that they have a generally constant diameter which is similar to the diameter of the generally spherical cavity 48 of the bearing 42 (shown in Figures 13 and 14), and the recessed surfaces 56 are recessed relative to the diameter of the curved surfaces 44. That is, the curved surfaces 44 extend radially further from a central point in the ball portion 52 than the recessed surfaces 56. In the exemplary embodiment, the curved surfaces 44 are diametrically opposite of one another, and the recessed surfaces 56 are diametrically opposite of one another. In the exemplary embodiment, the recessed surfaces 56 of the ball portion 52 are generally flat in shape. However, it should be appreciated that the recessed surfaces 56 could take a range of different shapes.

[0033] Referring back to Figure 4-6, the diameter of the curved surfaces 44 of the ball portion 52 of the stud 32 is similar to the diameter of the spherical cavity 48 (shown in Figures 13 and 14) of the bearing 42 to allow, thus allowing for sliding contact between the curved surfaces 44 of the stud 32 and the bearing surface 46 of the bearing 42. As shown, the ball portion 52 of the stud 32 is captured by the bearing surface 46 on both sides of an equator of the ball portion 52. That is, the single bearing 42 with the single bearing surface 46 supports both an upper hemisphere and a lower hemisphere of the ball portion 52. This enables the relative pivoting or rotation of the housing 34 relative to the stud 32 shown in Figures 4-6. A lubricant (not shown), such as grease, is preferably employed to provide a low friction interface between the curved surfaces 44 of the stud 32 and the bearing surface 46 of the bearing 42.

[0034] Referring now to Figures 13-16, the bearing 42 includes a passage which is shaped for guiding the ball portion 52 (shown in Figures 8-11) of the stud 32 into the spherical cavity 48 of the bearing 42. The passage extends axially from one of the open ends of the bearing 42 to the shaped cavity. In the exemplary embodiment, the passage is defined by a pair of slots 58 which extend to one of the open ends of the bearing 42. As such, as shown in Figure 15, when viewed from above, the passage in the bearing 42 is generally oval in shape with a pair of long sides and a pair of curved sides.

[0035] Referring back to Figures 4-6, the ball joint assembly 26 further includes a pair of dust boots 60 which establish fluid-tight seals between the housing 34 and the stud 32 to hold the lubricant within the ball joint assembly 26 and also to protect the internal components of the ball joint assembly 26 from external debris. The dust boots 60 may be engaged with the stud 32 and the housing 34 through any suitable connection means.

[0036] Assembly of the ball joint assembly 26 includes separately forming the housing 34 with the integrally connected bearing 42 and the stud 32. The stud 32 is then oriented such that the curved surfaces 44 of the ball portion 52 are aligned with the slots 58 of the passage 50, and the ball portion 52 is inserted axially into the spherical cavity 48 of the bearing 42. Once the ball portion 52 of the stud 32 is received within the spherical cavity 48 of the bearing 42, then the stud 32 is rotated by relative to the housing 34, for example, by ninety degrees 90°) to slidably engage the curved surfaces 55 of the ball portion 52 with the bearing surface 44 of the bearing 42. Then, the dust boots 60 are engaged with the housing 34 and stud 32 to protect the interior of the ball joint assembly 20. This process is less laborious and less costly than the processes of assembling other known bushing assemblies.

[0037] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims.