Lightweight heavy duty bushing with easy assembly

Abstract

A lightweight heavy duty bushing assembly for use in a vehicle suspension system and being low cost and having a high assembly tolerance is disclosed. A metal bar pin is press fit into a bushing formed from a metal sleeve bonded to an elastomeric housing. The metal sleeve is deformable such that exact tolerances of the metal sleeve and the bar pin are not required. The metal bar pin has extended ends with a hole in each end for attachment of the metal bar pin to vehicle suspension components, mounting brackets, or to the vehicle frame.

1 . A bushing assembly comprising:
 a deformable inner metal sleeve;   an elastomeric housing secured to said deformable inner metal sleeve;   a metal bar pin press fit into said deformable inner metal sleeve, wherein said deformable inner metal sleeve has a non-circular cross section while containing said metal bar pin.   
   
   
       2 . The bushing assembly of  claim 1  wherein said deformable inner metal sleeve is made of steel. 
   
   
       3 . The bushing assembly of  claim 1  wherein said elastomeric housing is rubber. 
   
   
       4 . The bushing assembly of  claim 1  wherein said elastomeric housing is bonded to said deformable inner metal sleeve. 
   
   
       5 . The bushing assembly of  claim 1  wherein said metal bar pin is cast metal. 
   
   
       6 . The bushing assembly of  claim 5  wherein said metal is iron. 
   
   
       7 . The bushing assembly of  claim 1  wherein said metal bar pin has a central section with a four point cruciform cross section. 
   
   
       8 . The bushing assembly of  claim 7  wherein two of the extension end surfaces of said cruciform cross section are in full contact with said deformable inner metal sleeve and two of the extension end surfaces of said cruciform cross section are only in line contact with the deformable inner metal sleeve. 
   
   
       9 . The bushing assembly of  claim 1  wherein said metal bar pin has a central section with a three point cross section. 
   
   
       10 . The bushing assembly of  claim 1  wherein said metal bar pin has a central section with a five point cross section. 
   
   
       11 . The bushing assembly of  claim 1  wherein said metal bar pin has a central section with a six point cross section. 
   
   
       12 . The bushing assembly of  claim 1  wherein said metal bar pin extends beyond each end of said deformable inner metal sleeve. 
   
   
       13 . The bushing assembly of  claim 12  wherein each of said extended ends of said metal bar pin has a hole through it. 
   
   
       14 . (canceled) 
   
   
       15 . (canceled) 
   
   
       16 . The bushing assembly of  claim 1  wherein the central section of said metal bar pin is comprised of voids bounded by radially extending contact surfaces. 
   
   
       17 . A method of assembling said bushing assembly of  claim 1  by press fitting said bar pin into said deformable inner metal sleeve, wherein said deformable inner metal sleeve deforms from a circular cross section to a non-circular cross section.