Structural I-beam automotive suspension arm

A structural element formed from sheet metal comprising a vehicular suspension arm including:

• a) a sheet metal stamped component press-formed from sheet aluminum, sheet steel or similar sheet metal materials of uniform thickness comprising a central web portion and two flange portions at opposite sides of said central web portion;
• b) said central web portion configured as a single material thickness and including an extruded opening at a predetermined point adapted to create a suitable structure to accept a ball joint of a spindle assembly;
• c) said flange portions comprising upstanding and downstanding sections and including at least one discontinuity creating a suitable structure to accept vehicle body attachment details;
• d) said upstanding and downstanding sections each configured with a continuous contiguous double returned segment of said sheet metal, whereby the thickness of each flange portion is two times the thickness of the central web portion;
• wherein the trim ends of the sheet metal terminate against the central web portion and are rigidly fixed to the central web portion via MIG, TIG, Arc or laser welding or similar means, so that the structural element is of an I-beam section whereby the thickness of each flange portion is double the thickness of the central web portion.

A structural element formed from sheet metal comprising a vehicular suspension arm including:

• a) a sheet metal stamped component press-formed from sheet aluminum, sheet steel or similar sheet metal materials of uniform thickness comprising a central web portion and two flange portions at opposite sides of said central web portion;
• b) said central web portion configured as a single material thickness and including an extruded opening at a predetermined point adapted to create a suitable structure to accept a ball joint of a spindle assembly;
• c) said flange portions comprising upstanding and downstanding sections and including at least one discontinuity creating a suitable structure to accept vehicle body attachment details;
• d) said upstanding and downstanding sections each configured with a continuous contiguous double returned segment of said sheet metal, whereby the thickness of each flange portion is two times the thickness of the central web portion;
• wherein the trim ends of the sheet metal terminate a small distance from the central web portion creating a gap, and the trim ends are rigidly fixed to both the central web portion and the continuous double returned segment via MIG, TIG, Arc or laser welding or similar means, so that the structural element is of an I-beam section whereby the thickness of each flange portion is double the thickness of the central web portion.

A structural element formed from sheet metal comprising a vehicular suspension arm including:

• a) a sheet metal stamped component press-formed from sheet aluminum, sheet steel or similar sheet metal materials of uniform thickness comprising a central web portion and two flange portions at opposite sides of said central web portion;
• b) a bushing support structure press-formed from a similar material to said sheet metal stamped component and configured to be rigidly attached to said sheet metal stamped component via MIG, TIG, Arc or laser welding or similar means;
• c) said bushing support structure configured as a simple open or closed section and adapted to accept vehicle body attachment details;
• d) said central web portion configured as a single material thickness and including an extruded opening at a predetermined point adapted to create a suitable structure to accept a ball joint of a spindle assembly;
• e) said flange portions comprising upstanding and downstanding sections and including at least one discontinuity creating a suitable structure to accept additional vehicle body attachment details;
• f) said upstanding and downstanding sections each configured with a continuous contiguous double returned segment of said sheet metal, whereby the thickness of each flange portion is two times the thickness of the central web portion;
• wherein the trim ends of the sheet metal terminate against the central web portion and are rigidly fixed to the central web portion via MIG, TIG, Arc or laser welding or similar means, so that the structural element is of an I-beam section whereby the thickness of each flange portion is double the thickness of the central web portion.

A structural element formed from sheet metal comprising a vehicular suspension arm including:

• a) a sheet metal stamped component press-formed from sheet aluminum, sheet steel or similar sheet metal materials of uniform thickness comprising a central web portion and two flange portions at opposite sides of said central web portion;
• b) a bushing support structure press-formed from a similar material to said sheet metal stamped component and configured to be rigidly attached to said sheet metal stamped component via MIG, TIG, Arc or laser welding or similar means;
• c) said bushing support structure configured as a simple open or closed section and adapted to accept vehicle body attachment details;
• d) said central web portion configured as a single material thickness and including an extruded opening at a predetermined point adapted to create a suitable structure to accept a ball joint of a spindle assembly;
• e) said flange portions comprising upstanding and downstanding sections and including at least one discontinuity creating a suitable structure to accept additional vehicle body attachment details;
• f) said upstanding and downstanding sections each configured with a continuous contiguous double returned segment of said sheet metal, whereby the thickness of each flange portion is two times the thickness of the central web portion;
• wherein the trim ends of the sheet metal terminate a small distance from the central web portion creating a gap, and the trim ends are rigidly fixed to both the central web portion and the continuous double returned segment via MIG, TIG, Arc or laser welding or similar means, so that the structural element is of an I-beam section whereby the thickness of each flange portion is double the thickness of the central web portion.