Claims:We claim:

1. A lower control arm (100) for a front suspension system of a vehicle, the lower control arm (100) comprising:
a first elongated hollow member (101) defined with a first provision (102) at one end and a second provision (103) at other end; and
a second elongated hollow member (104) having a first end (104a) and a second end (104b), wherein,
the first end (104a) of the second elongated hollow member (104) is thermally joined to the first elongated hollow member (101) at a pre-determined location, and
a third provision (105) is defined at the second end (104b);
wherein, each of the first elongated hollow member (101) and the second elongated hollow member (104) are one-piece structures.

2. The lower control arm (100) as claimed in claim 1, wherein the first elongated hollow member (101) and the second elongated hollow member (104) are seamless tubes.

3. The lower control arm (100) as claimed in claim 1, wherein the pre-determined location is any position along the length of the first elongated hollow member (101).

4. The lower control arm (100) as claimed in claim 1, wherein the first provision (102) is configured to receive a bushing (106) for connecting the first elongated hollow member (101) to a frame of the vehicle.

5. The lower control arm (100) as claimed in claim 1, wherein the second provision (103) is configured to accommodate a sleeve (107) for connecting the first elongated hollow member (101) to a tie rod.

6. The lower control arm (100) as claimed in claim 1, wherein the third provision (105) is configured to receive a ball socket joint (108) to connect the second elongated hollow member (104) to a steering knuckle.

7. The lower control arm (100) as claimed in claim 1, wherein the first elongated hollow member (101) and the second elongated hollow member (104) forms a substantially triangular shaped component.

8. The lower control arm (100) as claimed in claim 1 comprises one or more reinforcement members (109) thermally joined at pre-determined locations between the first elongated hollow member (101) and the second elongated hollow member (104).

9. The lower control arm (100) as claimed in claim 1, wherein the first elongated hollow member (101) and the second elongated hollow member (104) are defined with at least one of rectangular and square cross-section.

10. A lower control arm (200) for a front suspension system of a vehicle, the lower control arm (200) comprising:
a hollow member (201) configured as a one-piece structure having a first portion (202) and a second portion (203), wherein the first portion (202) and the second portion (203) forms a substantially L-shaped member,
wherein, the hollow member (201) is defined with a first provision (204) at one end, a second provision (205) at other end, and a third provision (206) in an outer periphery (207a) of an interconnecting region of the first portion (202) and the second portion (203) of the hollow member (201); and
a reinforcement member (208) thermally joined to an inner periphery (207a) of the interconnecting region of the first portion (202) and the second portion (203).

11. A front suspension system of a vehicle comprising a lower control arm (100) as claimed in claim 1.

, Description:TECHNICAL FIELD

The present disclosure generally relates to the field of automobiles. Particularly, but not exclusively, the present disclosure relates to suspension system of a vehicle. Further embodiments of the present disclosure disclose a lower control arm for a front suspension system of the vehicle.

BACKGROUND

During movement or operation of a vehicle, a variety of forces act upon the wheels of the vehicle. These forces may be transferred from the wheels to the vehicle frame and its related components. The vehicle may be subjected to vertical loads and are frequently encountered when the vehicle travels, particularly over bumps or holes in the road. These loads may also act when the vehicle is travelling along an incline. In addition, longitudinal forces may act upon the wheels against the direction of travel while the vehicle is moving. Further, the vehicle may also be subjected to centrifugal forces during turning. Generally, vehicles are employed with suspension systems for connecting wheels to a vehicle frame. The suspension system allows relative motion between the wheels and the vehicle frame and absorbs vibrations of the road during operation of the vehicle. The suspension system may withstand all the forces acting on the vehicle.

In the modern vehicles such as passenger cars, the design of front and rear suspension may be different to obtain better ride quality, and to improve performance of the vehicle. Generally, in such vehicles, the front suspension may be configured as independent suspension which allows independent movement of front wheel on each side to respond to the road conditions.

In such vehicles, at least one link or control arm may be used to couple the wheels to the frame of the vehicle. Such suspension components may be sufficiently rigid or stiff to accommodate all of the forces – vertical, longitudinal and centrifugal acting on the vehicle without crack or fracture.

Conventionally, control arm of the vehicle may be formed out a stamping process, wherein the control arm may consist of a top shell and a bottom shell. The top shell and the bottom shell may be defined with a number of provisions to provide connection with the vehicle parts. The top shell may then be joined with the bottom shell through welding at various locations such as along periphery of the bottom shell and other portions that may be needed for connection. This way the control arm may be formed as part of the front suspension system.

However, the conventionally known control arm may add to overall weight of the vehicle significantly and may be complex as it involves welding extensively. Also, since welding is used, the dimensional accuracy of the control arm may not be as accurate as required.

The present disclosure is directed to overcome the one or more problems stated above or any other limitations associated with the conventional arts.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of conventional assemblies are overcome and additional advantages are provided through the assembly as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the disclosure a lower control arm for a front suspension system of a vehicle is disclosed. The lower control arm comprises a first elongated hollow member defined with a first provision at one end and a second provision at other end. The lower control arm also includes a second elongated hollow member having a first end and a second end. The first end of the second elongated hollow member is thermally joined to the first elongated hollow member at a pre-determined location, and a third provision is defined at the second end. Each of the first elongated hollow member and the second elongated hollow member are one-piece structures.

In an embodiment of the disclosure, the first elongated hollow member and the second elongated hollow member are seamless tubes.

In an embodiment of the disclosure, the predetermined location is any position along the length of the first elongated hollow member.

In an embodiment of the disclosure, the first provision is configured to receive a bushing for connecting the first elongated hollow member to a frame of the vehicle.

In an embodiment of the disclosure, the second provision is configured to accommodate a sleeve for connecting the first elongated hollow member to a tie rod.

In an embodiment of the disclosure, the third provision is configured to receive a ball socket joint to connect the second elongated hollow member to a steering knuckle.

In an embodiment of the disclosure, the first elongated hollow member and the second elongated hollow member forms a substantially triangular shaped component.

In an embodiment of the disclosure, the lower control arm comprises one or more reinforcement members thermally joined at pre-determined locations between the first elongated hollow member and the second elongated hollow member.

In an embodiment of the disclosure, the first elongated hollow member and the second elongated hollow member are defined with at least one of rectangular and square cross-section.

In another non-limiting embodiment of the disclosure, a lower control arm for a front suspension system of a vehicle is disclosed. The lower control arm comprises a hollow member configured as a one-piece structure having a first portion and a second portion. The first portion and the second portion forms a substantially L-shaped member. The hollow member is defined with a first provision at one end, a second provision at other end, and a third provision in an outer periphery of an interconnecting region of the first portion and the second portion of the hollow member. The lower control arm also includes a reinforcement member thermally joined to an inner periphery of the interconnecting region of the first portion and the second portion.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, and further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:

FIG.1 illustrates a perspective view of a lower control arm for a front suspension system of a vehicle, in accordance with an embodiment of the present disclosure.

FIG.2 illustrates perspective view of the lower control arm of FIG.1, in accordance with another embodiment of the present disclosure.

FIG.3 illustrates perspective view of the lower control arm, in accordance with some embodiment of the present disclosure.

FIG.4 illustrates perspective view of the lower control arm of FIG.3, in accordance with another embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

While the embodiments in the disclosure are subject to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

It is to be noted that a person skilled in the art would be motivated from the present disclosure and would modify various constructions of the lower control arm, which may vary from one vehicle to vehicle. However, such modifications should be considered to be within the scope of the disclosure. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present disclosure, so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

The lower control arm of the present disclosure may be employed in any kind of vehicle ranging from passenger vehicles to commercial vehicles.

The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.

Embodiments of the present disclosure disclose a lower control arm for a front suspension system of a vehicle. The lower control arm of the present disclosure may be configured to support front suspension system of the vehicle. Independent lower control arms may be provided for each of the front wheels.

The lower control arm of the present disclosure may broadly include a first elongated hollow member and a second elongated hollow member. Both the first hollow member and the second hollow member may be made as a one-piece structure. In an embodiment, the first hollow member and the second hollow member may be configured as seamless tubes and may be formed through extrusion. In an embodiment, the seamless tubes of standard section may be readily available. The first hollow member and the second hollow member may be made of aluminium material or alloys of aluminium or any other metallic material which may easily formable.

The first hollow member may consist of provisions for connecting the lower control arm to parts of the vehicle. In an embodiment, the first hollow member may be defined with a first provision at one end and a second provision at the other end. The first provision may be configured to receive a mount bushing to connect the first hollow member with a frame or chassis of the vehicle and the second provision may be configured to accommodate a sleeve. The sleeve facilitates connection of the first hollow member with a tie rod. The first hollow member may have rectangular cross-section or square cross-section.

Further, the second hollow member may be joined with the first hollow member. It may be joined through thermal joining process such as but not limiting to welding. The second hollow member has two ends – a first end and a second end. In an embodiment, the second hollow member may be joined to the first hollow member through the first end while at the second end, a third provision may be defined. The third provision may be adapted to accommodate a ball-socket joint to connect the second hollow member, in turn the lower control arm with a steering knuckle. In an embodiment, the second hollow member may be joined with the first hollow member at any position along the length of the first hollow member. The lower control arm may also consist of one or more reinforcement members that may be joined at an interconnecting region of the first hollow member and the second hollow member. The reinforcement members provide additional stiffness to the lower control arm.

In another embodiment of the present disclosure, there may be a one-piece hollow member consisting of a first portion and a second portion, where suitable provisions may be defined at these portions so as to be connectable to parts of the vehicle. A first provision may be defined at one end of the first portion and a second provision may be defined at one end of the second portion. The first provision may be configured to receive a mount bushing to connect the lower control arm to the frame of the vehicle and the second provision may be configured to receive a ball socket joint to connect the second portion of the lower control arm to the steering knuckle. There may also be a third provision defined in an outer periphery of an interconnecting region of the first portion and the second portion of the hollow member and the third provision may be configured to receive a sleeve to connect the hollow member to the tie rod. Further, one or more reinforcement members may be provided on an inner periphery of the interconnecting region of the first portion and the second portion.

The following paragraphs describe the present disclosure with reference to FIGS. 1 to 4. In the figures, the same element or elements which have similar functions are indicated by the same reference signs. In the figures, the vehicle and the suspension system is not illustrated for the purpose of simplicity.

FIG.1 illustrates a perspective view of a lower control arm (100). The lower control arm (100) of the present disclosure is preferably for a front suspension system of the vehicle. The lower control arm (100) may accommodate several components of the front suspension system connecting to various parts of the vehicle.

The lower control arm (100) as shown in FIG.1 may generally consist of a first elongated hollow member (101), also referred to herein as first hollow member (101) and a second elongated hollow member (104), also referred to herein as second hollow member (104). The first hollow member (101) and the second hollow member (104) may be both formed as one-piece structure, i.e. without any joints in them. In an embodiment, they may be formed by an extrusion process, however they may be manufactured using other process as well and the same should not be construed as a limitation to the present disclosure. In an embodiment, both the first hollow member (101) and the second hollow member (104) may be made as seamless tubes using the extrusion manufacturing process. In an embodiment, the seamless tubes of standard section may be readily available. The first hollow member (101) and the second hollow member (104) may be made of any metallic material including but not limiting to Aluminium material or alloys of Aluminium.

Referring to FIG.2 in conjunction with FIG.1, the first hollow member (101) may be defined with a first provision (102) and a second provision (103) at either ends of the first hollow member (101). The first provision (102) and the second provision (103) are each configured to accommodate components to connect the lower control arm (100) with the parts of the vehicle. In an embodiment, the first provision (102) may be adapted to receive a mount bushing (106) to connect the first hollow member (101) of the lower control arm (100) with a frame of the vehicle. The bushing (106) may be made of a polymeric material and is configured to dampen the vibrations of the vehicle. Further, the second provision (103) may be configured to accommodate a sleeve (107) which may connect to tie rod of the vehicle. The first hollow member (101) may be of rectangular or square cross-section.

In an embodiment, the second hollow member (104) may be joined to the first hollow member (101). The second hollow member (104) may be joined thermally using the process such as welding. The second hollow member (104) consists of a first end (104a) and a second end (104b), the first end (104a) may be joined with the first hollow member (101), while at the second end (104b) of the second hollow member (104) a third provision (105) may be defined. The third provision (105) may be configured to receive a ball-socket joint (108) to connect the second hollow member (104) of the lower control arm (100) to a steering knuckle [not shown in the figure]. Further, the first end (104a) of the second hollow member (104) may be configured to join at any portion of the first hollow member (101) along its length. In an embodiment, the second hollow member (104) may be joined at a substantially central portion of the first hollow member (101). The configuration of the first hollow member (101) and the second hollow member (104) may facilitate modularity of the lower control arm (100), such that the lower control arm (100) may be employed in any configuration of the vehicle with minor modifications.

Further, as shown in FIG.1, the lower control arm (101) consists of one or more reinforcement members (109) joined at a junction or interconnecting region of the first hollow member (101) and the second hollow member (104). In an embodiment, the reinforcement members (109) may be joined by any suitable techniques such as but not limited to welding. The reinforcement member (109) may provide additional stiffness to the lower control arm (100).

Moving on FIG.2, it illustrates perspective view of another embodiment of the lower control arm (100). As can be seen from FIG.2, the second hollow member (104) may be broader at the first end (104a) where it may be joined with the first hollow member (101). Since the region around first end (104a) of the second hollow member (104) is broader, there may be no reinforcement members provided at the interconnecting region of the first hollow member (101) and the second hollow member (104). In an embodiment, the broader first end (104a) may provide the necessary additional stiffness to the lower control arm (100).

Referring now to FIG.3, it shows perspective view of another embodiment of the lower control arm (200) of the present disclosure. In this embodiment, there may be a single one-piece hollow member (201) which may consist of a first portion (202) and a second portion (203). The first portion (202) and the second portion (203) interconnect forming a substantially L-shaped member. The first portion (202) defines a first provision (204) at its end and the second portion (203) defines a second provision (205) at its end. Here, the first provision (204) may be configured to receive a bushing (106) to connect the first portion (202) of the hollow member (201) to the frame of the vehicle. Further the second provision (205) may be configured to receive a ball socket joint (108) to connect the second portion (203) of the hollow member (201) to the steering knuckle. At the interconnecting region of the first portion (202) and the second portion (203), at an outer periphery (207a), a third provision (206) may be defined. The third provision (206) may be configured to receive a sleeve (107) which connects the lower control arm (200) with the tie rod of the vehicle.

In an embodiment of the present disclosure, the single one-piece hollow member (201) may be configured with the first portion (202) and the second portion (203) by a bending process.

As can be seen from FIG.3, at an inner periphery (207b) of the hollow member (201), a reinforcement member (208) may be joined. As described earlier, the reinforcement member (208) adds to the stiffness of the hollow member (201). Further, as shown in FIG.4, the reinforcement member (208) may also be provided on the outer periphery (207a) of the hollow member (201). In an alternate embodiment shown in FIG.4, the first portion (202) and the second portion (203) may form a substantially U-shaped member.

In an embodiment of the disclosure, the lower control arm of the front suspension system may be light weight and has less welding requirement thus improving the dimensional accuracy of the lower control arm.

In an embodiment of the disclosure, the lower control arm shows significant improvement in stiffness and has lesser number of parts, thus reducing the complexity.

It is to be understood that a person of ordinary skill in the art may develop a lower control arm of similar configuration without deviating from the scope of the present disclosure. Such modifications and variations may be made without departing from the scope of the present invention. Therefore, it is intended that the present disclosure covers such modifications and variations provided they come within the ambit of the appended claims and their equivalents.

Equivalents:

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.” While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals:

100 Lower control arm
101 First elongated hollow member / First hollow member / First member
102 First provision
103 Second provision
104 Second elongated hollow member / Second hollow member / Second member
104a First end of the second hollow member
104b Second end of the second hollow member
105 Third provision
106 Bushing
107 Sleeve
108 Ball socket joint
109 Reinforcement member(s)
200 Lower control arm
201 Hollow member
202 First portion of the hollow member
203 Second portion of the hollow member
204 First provision
205 Second provision
206 Third provision
207a Outer periphery of the hollow member
207b Inner periphery of the hollow member
208 Reinforcement member