US-12617462-B2 - Rod assembly

US12617462B2US 12617462 B2US12617462 B2US 12617462B2US-12617462-B2

Abstract

A rod, such as a radius rod, is provided. The radius rod may include a carbon fiber tube member that includes an aperture extending from one end of the tube member through the opposing end of the tube member. The radius rod may further include an inner threaded rod member located within the carbon fiber tube member. The radius rod may further include two rod couplers threaded onto opposing ends of the inner threaded rod member, wherein a portion of the rod couplers extend into the carbon fiber tube member and engage the carbon fiber tube member on each end to maintain the inner threaded rod member coaxial with the carbon fiber tube member when not under load. Further, the radius rod may include two rod end members, each rod end member coupled to one rod coupler.

Inventors

Todd Zuccone

Assignees

Todd Zuccone

Dates

Publication Date: 20260505
Application Date: 20231213

Claims (15)

1 . A radius rod assembly for use in a suspension of a vehicle comprising at least one radius rod, wherein the at least one radius rod comprises: a tube member comprising carbon fiber and having an aperture extending from a first end of the tube member through a second end of the tube member; an inner threaded rod member located within the tube member; two rod couplers threaded onto opposing ends of the inner threaded rod member, the inner threaded rod member drawing the two rod couplers together for added strength and inhibiting the rod couplers from coming loose, wherein a portion of each of the two rod couplers extends into the tube member and is bonded to the tube member on the first and second ends to maintain the inner threaded rod member coaxial with the tube member when the tube member is not under load; and two rod end members, each of the two rod end members coupled to one rod coupler of the two rod couplers, wherein the two rod couplers are fixedly secured to the tube member and wherein the two rod end members couple the radius rod to suspension components of the vehicle.
2 . The radius rod assembly of claim 1 , wherein a first rod end member of the two rod end members is coupled to a shear plate and a frame.
3 . The radius rod assembly of claim 2 , wherein a second rod end member of the two rod end members is coupled to a wheel component.
4 . The radius rod assembly of claim 3 , further comprising a plurality of radius rods.
5 . The radius rod assembly of claim 1 , wherein the inner threaded rod member comprises aluminum.
6 . A radius rod assembly comprising at least one radius rod, wherein the at least one rod comprises: at least two tube members comprising carbon fiber, each of the at least two tube members having an aperture extending from a first end of each of the at least two tube members through a second end of each of the at least two tube members; an inner threaded rod member located within each of the at least two tube members; each of the inner threaded rod members having opposing ends; at least one center coupler provided between one of the opposing ends of each of the inner threaded rods; two rod couplers respectively threaded onto an opposite one of the opposing ends of each of the inner threaded rod members, the inner threaded rod members drawing the two rod couplers together toward the at least one center coupler for added strength and inhibiting the rod couplers from coming loose, wherein a portion of each of the two rod couplers extends into each of the at least two tube members and is bonded to the at least two tube members on the first and second ends and the at least one center coupler extending into and bonded to each of the at least two tube members, the two rod couplers and the at least one center coupler operating to maintain each of the inner threaded rod members coaxial with each of the at least two tube members when each of the at least two tube members is not under load; and two rod end members, each of the two rod end members coupled to one rod coupler of the two rod couplers, wherein the two rod end members couple the at least one radius rod to suspension components of a vehicle.
7 . The radius rod assembly of claim 6 , wherein the two rod couplers are fixedly secured to each of the at least two tube members.
8 . The radius rod assembly of claim 6 , wherein a first rod end member of the two rod end members is coupled to a shear plate and a frame.
9 . The radius rod assembly of claim 8 , wherein a second rod end member of the two rod end members is coupled to a wheel component.
10 . The radius rod assembly of claim 9 , further comprising a plurality of radius rod assemblies.
11 . The radius rod assembly of claim 6 , wherein each of the inner threaded rod members comprises aluminum.
12 . A method of making a radius rod for use with a vehicle, wherein the method comprises: providing a tube member comprising carbon fiber and having an aperture extending from a first end of the tube member through a second end of the tube member; locating an inner threaded rod member within the tube member; threadingly coupling two rod couplers onto opposing ends of the inner threaded rod member; drawing the two rod couplers together for added strength and inhibiting the rod couplers from coming loose; extending a portion of each of the two rod couplers into the tube member and bonding the tube member on the first and second ends to maintain the inner threaded rod member coaxial with the tube member when the tube member is not under load; providing two rod end members; and coupling each of the two rod end members to one rod coupler of the two rod couplers; and fixedly securing the two rod couplers to the tube member, wherein the two rod end members are configured to couple the radius rod to suspension components of the vehicle.
13 . The method of claim 12 , further comprising coupling a first rod end member of the two rod end members to a shear plate and a frame.
14 . The method of claim 13 , further comprising coupling a second rod end member of the two rod end members to a wheel component.
15 . The method of claim 12 , wherein the inner threaded rod member comprises aluminum.

Description

BACKGROUND OF THE INVENTION Technical Field This invention relates generally to a rod, and more particularly to a radius rod formed of carbon fiber. State of the Art Off-road vehicles are becoming more and more prevalent in ownership, use, racing and so forth. Particularly, utility terrain vehicles (UTVs) are the typical off-road vehicle type that people purchase and utilize. UTVs and other off-road vehicles have a suspension to handle the rigors of driving over uneven, rocky, and otherwise non-flat surfaces. The use of suspension operates to maximize the contact and friction between the tires of the vehicle and the ground surface, to stay stable in the rocky, uneven terrain and so forth. Part of the suspension system on off-road vehicles are radius rods. A radius rod is a suspension link intended to control wheel motion in the longitudinal (fore-aft) direction. The radius rod is typically connected on one end to the wheel carrier or axle and on the other end to the chassis or frame of the vehicle. Radius rods are typically formed of steel and are heavy and detrimental to uses, such as racing. Rods of this type are also employed in steering systems, such as tie rods. Accordingly, there is a need in the industry for rods, such as radius rods, formed of carbon fiber that provides the support of conventional radius rods, but with less weight. SUMMARY OF THE INVENTION An embodiment includes a rod assembly comprising at least one rod, wherein the at least one rod comprises: a tube member comprising carbon fiber and having an aperture extending from a first end of the tube member through a second end of the tube member; an inner threaded rod member located within the tube member; two rod couplers threaded onto opposing ends of the inner threaded rod member, wherein a portion of each of the two rod couplers extends into the tube member and engages the tube member on the first and second ends to maintain the inner threaded rod member coaxial with the tube member when the tube member is not under load; and two rod end members, each of the two rod end members coupled to one rod coupler of the two rod couplers. The two rod couplers may be fixedly secured to the tube member. A first rod end member of the two rod end members may be coupled to a shear plate and a frame. A second rod end member of the two rod end members may be coupled to a wheel component. The rod assembly may further comprise a plurality of rods. The inner threaded rod member may comprise aluminum. The rod assembly may be a radius rod assembly for a suspension system. An embodiment includes a rod assembly comprising at least one rod, wherein the at least one rod comprises: at least two tube members comprising carbon fiber, each of the at least two tube members having an aperture extending from a first end of each of the at least two tube members through a second end of each of the at least two tube members; an inner threaded rod member located within each of the at least two tube members; each of the inner threaded rod members having opposing ends; at least one center coupler provided between one of the opposing ends of each of the inner threaded rod members; two rod couplers respectively threaded onto an opposite one of the opposing ends of each of the inner threaded rod members, wherein a portion of each of the two rod couplers extends into each of the at least two tube members and engages the at least two tube members on the first and second ends to maintain each of the inner threaded rod members coaxial with each of the at least two tube members when each of the at least two tube members is not under load; and two rod end members, each of the two rod end members respectively coupled to one rod coupler of the two rod couplers. The two rod couplers may be fixedly secured to each of the at least two tube members. A first rod end member of the two rod end members may be coupled to a shear plate and a frame. A second rod end member of the two rod end members may be coupled to a wheel component. The rod assembly may further comprise a plurality of rod assemblies. Each of the inner threaded rod members may comprise aluminum. The rod assembly may be a radius rod assembly for a suspension system. Another embodiment includes a method of making a rod, wherein the method comprises: providing a tube member comprising carbon fiber and having an aperture extending from a first end of the tube member through a second end of the tube member; locating an inner threaded rod member within the tube member; threadingly coupling two rod couplers onto opposing ends of the inner threaded rod member, extending a portion of each of the two rod couplers into the tube member and engaging the tube member on the first and second ends to maintain the inner threaded rod member coaxial with the tube member when the tube member is not under load; providing two rod end members; and coupling each of the two rod end members to one rod coupler of the two rod couplers. The method may furt