Spring isolation pad with spring rotation stop and pad rotation stop

Abstract

The present disclosure provides a spring isolation pad having a spring rotation stop and a pad rotation stop. A spring isolation pad for a suspension assembly of a vehicle may be provided. The spring isolation pad may include a rubber isolation pad for supporting a coil spring operably coupled to the control arm, and a structural insert for supporting the coil spring and the rubber isolation pad. The rubber isolation pad may be operably coupled to the structural insert and include a first plurality of extensions. The structural insert may include a second plurality of extensions and a base. The control arm may include a spring link having an aperture. The structural insert may be engaged with the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle via the first plurality of extensions and the second plurality of extensions.

Description

Technical Field

[0001] Example embodiments relate generally to suspension components and, more particularly, to a spring spacer for restraining a coil spring and a coil spring support element of a strut of a vehicle. Background Art

[0002] Some vehicles utilize a suspension assembly that is relatively free of complexity to provide ease of manufacturing. In these cases, the suspension assembly may include various suspension components that may include, but are not limited to, a coil spring, a control arm, a spring link, a rubber spacer, and a spring spacer. The spring link, the rubber spacer, and the spring spacer may work together to help prevent the coil spring from rotating relative to the control arm during a compression cycle.

[0003] To prevent and limit the rotation of the coil spring within the suspension assembly, rubber isolation pads are often used with spring links to limit the rotation. However, during operation of the vehicle, the coil spring is subject to various changes in load and tension, which may cause subsystems of the suspension assembly to rotate. The rotation of the coil spring may result in reduced performance. Therefore, it may be necessary to add further support to the rubber isolation pad and the suspension assembly without adding new parts that may compromise the efficiency and weight of the suspension assembly and vehicle. Summary of the invention

[0004] According to an example embodiment, a spring isolation pad for a suspension assembly of a vehicle may be provided. The spring isolation pad may include a rubber isolation pad for supporting a coil spring operably coupled to a control arm, and a spring isolation pad for supporting the coil spring and the rubber isolation pad. The rubber isolation pad may be operably coupled to the spring isolation pad and include a first plurality of extensions. A structural insert may include a second plurality of extensions and a base. The control arm may include a spring link having an orifice. The structural insert may engage the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle via the first plurality of extensions and the second plurality of extensions.

[0005] In another example embodiment, a suspension assembly for a vehicle of an example embodiment may be provided. The suspension assembly may include: a coil spring disposed below a chassis of the vehicle; a control arm operably coupled to the coil spring and a wheel of the vehicle; a rubber isolation pad for supporting the coil spring; and a structural insert for supporting the coil spring and the rubber isolation pad. The control arm may include a spring link having an orifice. The rubber isolation pad may be disposed on the structural insert and include a first plurality of extensions. The structural insert may include a second plurality of extensions and a base. The structural insert may engage the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle via the first plurality of extensions and the second plurality of extensions. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Having thus generally described the invention, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0007] Figure 1 depicts a block diagram of a suspension assembly of a vehicle suspension system according to an example embodiment;

[0008] Figure 2 A perspective view of a suspension assembly of a vehicle suspension system is shown according to an example embodiment;

[0009] Figure 3 depicts a perspective view of a subsection of a suspension assembly according to an example embodiment;

[0010] Figure 4 shows an isolated view of a spring spacer according to an example embodiment;

[0011] Figure 5 depicts a cross-sectional side view of a spring spacer according to an example embodiment;

[0012] Figure 6 shows a perspective view of a structural insert according to an example embodiment;

[0013] Figure 7 depicts a top view of a structural insert according to an example embodiment;

[0014] Figure 8 shows a perspective view of a rubber isolation pad according to an example embodiment;

[0015] Fig. 9 depicts a side view of a rubber isolation pad according to an example embodiment; and

[0016] Fig.10A bottom view of a rubber isolation pad is shown according to an example embodiment. DETAILED DESCRIPTION

[0017] Some example embodiments will now be described more fully below with reference to the accompanying drawings, in which some but not all example embodiments are shown. In fact, the examples described and depicted herein should not be construed as limiting the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that the present disclosure will meet applicable requirements. The same reference numerals always refer to the same elements. In addition, as used herein, the term "or" will be interpreted as a logical operator whose result is true whenever one or more of its operands are true. As used herein, an operable connection should be understood to involve a direct or indirect connection, in which case the connection enables the functional interconnection of components that are operably connected to each other.

[0018] Some example embodiments described herein may address the above issues. In this regard, for example, some embodiments may provide a structural insert for a suspension system of a vehicle that may make the coil spring and the suspension system as a whole stronger and more efficient. Some embodiments may provide a structural insert that is an integral piece surrounded by a rubber isolation pad. Thus, installation of the suspension assembly may require less effort, fewer parts, less time, and may therefore be more efficient.

[0019] Figure 1 A block diagram of a suspension assembly 100 of a vehicle 10 is shown according to an example embodiment, and Figure 2 A perspective view of a suspension assembly for a vehicle suspension system according to an example embodiment is shown. Figure 1 to Figure 2As shown in , in some embodiments, the suspension assembly 100 may include a coil spring 110, a control arm 120, and a spring isolation pad 150. The spring isolation pad 150 may include a rubber isolation pad 130 and a structural insert 140. The suspension assembly 100 of the vehicle 10 may be operably coupled to the body 20 and the wheel 30 of the vehicle. In some cases, the vehicle 10 may include a chassis or a frame. The chassis or the frame may support and may form the basic structure of the vehicle 10. In an exemplary embodiment, the chassis and the frame may be formed by one or more cast subframes, and the coil spring 110 may be operably coupled to the chassis or the frame. In some cases, the vehicle may be a unibody, where the chassis / frame and the body 20 are one element. In some cases, the coil spring 110 may be part of the strut system of the vehicle. In this regard, the coil spring 110 may inhibit the articulation of the wheel 30, so that the movement of the wheel 30 may not be directly translated into the movement of the body 20. In doing so, the coil spring 110 can improve the ride quality perceived by passengers within the body 20 of the vehicle 10 by absorbing some of the forces in the bumps caused by the articulation of the wheel 30. Additionally, in example embodiments, the suspension assembly 100 can include a form of strut construction, and in this regard, the suspension assembly 100 can also play a role in the steering of the vehicle 10. To this end, the coil spring 110 can be operably coupled to the control arm 120, and the control arm 120 can act as a steering pivot for the wheel 30. The control arm 120 can be operably coupled to the wheel 30 on one side and to the chassis, frame, or body 20 on the other side. Regardless, in some cases, the shape of the coil spring 110 can be substantially helical.

[0020] The control arm 120 may also include a spring link 125. The spring link 125 may be disposed within a portion of the body of the control arm 120 and may be used to operably couple the control arm 120 and the coil spring 110. The spring link 125 may be operably coupled to the coil spring 110 via a rubber isolation pad 130 and a structural insert 140. The rubber isolation pad 130 and the structural insert 140 may engage the spring link 125 and the coil spring 110 to help operably couple the elements of the suspension assembly 100 together. The spring link 125, the rubber isolation pad 130, and the structural insert 140 together may help limit the rotation of the coil spring 110 via their structure and orientation. When under stress and tension from the operation of the vehicle 10 that causes the coil spring 110 to compress, the coil spring 110 may tend to rotate clockwise relative to the front of the vehicle 10. In some cases, the coil spring 110 may tend to rotate counterclockwise under compression. The rotational force of the coil spring 110 may cause force concentrations on various components of the suspension assembly 100. Therefore, the provided support and operable connection of the spring link 125, rubber isolation pad 130, and structural insert 140 may help balance the combined force transmitted by the coil spring 110 and increase the durability of the suspension assembly 100.

[0021] Figure 3 depicts a perspective view of a portion of a suspension assembly 100 according to an example embodiment, and Figure 4 An isolated view of a spring spacer 150 is shown according to an example embodiment. In this regard, Figure 3 The engagement between the spring link 125, the rubber isolation pad 130, and the structural insert 140 is depicted according to an example embodiment. In some cases, the rubber isolation pad 130 can completely surround the structural insert 140. In other words, the rubber isolation pad 130 can be a kind of housing or cover for the structural insert 140, which can extend completely around the structural insert 140 and surround the structural insert. Therefore, the structural insert 140 can be an underlying structure that can help support the rubber isolation pad 130 to improve the durability of the rubber isolation pad 130 while attempting to limit the rotation of the coil spring 110. In this regard, the structural insert 140 can be formed of a rigid material (such as a metal alloy) so as to have the strength to support the shape of the rubber isolation pad 130 operably coupled to the coil spring 110.

[0022] like Figure 4As shown, the structures of the rubber isolator 130 and the structural insert 140 can be similar to each other. The rubber isolator 130 can include a first plurality of extensions that can engage the coil spring 110 and the spring link 125. The structural insert 140 can have a second plurality of extensions that can engage the coil spring 110 and the spring link 125, and engage the first plurality of extensions. The second plurality of extensions of the structural insert 140 can include a first structural insert extension 141 and a second structural insert extension 142. The first structural insert extension 141 can project from the base 145 of the structural insert 140 in a first direction away from the coil spring 110 and substantially parallel to the longitudinal axis of the coil spring 110. The second structural insert extension 142 can project from the base 145 of the structural insert 140 in a second direction toward the coil spring 110 and substantially parallel to the longitudinal axis of the coil spring 110. A first rubber isolator extension 131 can project from the rubber isolator 130 in the first direction, and a second rubber isolator extension 132 can project from the rubber isolator 130 in the second direction. In some cases, since the rubber isolator 130 completely surrounds the structural insert 140, the first and second pluralities of extensions can be used for a similar functional purpose of restricting the rotation of the coil spring 110 during operation of the vehicle 10.

[0023] As Figures 2 to 3 shown, the first structural insert extension 141 and the first rubber isolator extension 131 can engage the aperture 126 of the spring link 125. The aperture 126 can be a drain hole for clearing water, dust, and debris from the spring link 125 and the suspension assembly 100 as a whole. In some cases, the second structural insert extension 142 and the second rubber isolator extension 132 can engage the end of the coil spring 110. Since the coil spring 110 can be urged to rotate in response to a compression cycle, the end of the coil spring 110 can bear against the second structural insert extension 142 and the second rubber isolator extension 132, and thus can apply a force on the rubber isolator 130 and the structural insert 140. However, accordingly, the first structural insert extension 141 and the first rubber isolator extension 131 can be operatively coupled to the aperture 126 of the spring link 125, which can restrict the rotation of the coil spring 110. In an exemplary embodiment, when not at maximum tension, the first structural insert extension 141 and the first rubber isolator extension 131 can move freely within the aperture 126 of the spring link 125. The size of the aperture 126 of the spring link can help restrict the maximum degree of rotation of the coil spring 110. In some cases, the coil spring 110 can be restricted to a 90-degree rotation.

[0024] In an example embodiment, second rubber isolation pad extension 132 may be a concave structure that may receive the end of coil spring 110. Second rubber isolation pad extension 132 may completely surround the end of coil spring 110. In some cases, second rubber isolation pad extension 132 may taper as second rubber isolation pad extension 132 protrudes further from rubber isolation pad 130. In an example embodiment, second rubber isolation pad extension 132 may be any structure or shape that may help secure and position the end of coil spring 110 with rubber isolation pad 130.

[0025] Figures 5 to 10 Different views of the rubber isolation pad 130 and the structural insert 140 are shown alone and in combination with one another. Figure 5 A cross-sectional view of a spring spacer 150 is depicted in accordance with an example embodiment. Figure 5 As shown in , the rubber isolation pad 130 can be supported by the structural insert 140 disposed therein. For example, the first rubber isolation pad extension 131 can be supported by the first structural insert extension 141, and the second rubber isolation pad extension 132 can be supported by the second structural insert extension 142. In some cases, the rubber isolation pad 130 can be made of rubber, polymer, or any other material to ensure the elastomeric properties of the rubber isolation pad 130. In example embodiments, the rubber isolation pad 130 may not be elastomeric and may be any number of materials to ensure the performance and durability of the coil spring 110 and the suspension assembly 100 as a whole. In example embodiments, the rubber isolation pad 130 can be used as a damper for the suspension assembly 100.

[0026] In some cases, the structural insert 140 may be made of aluminum, steel, or any number of metals or metallic materials that can support the rubber isolation pad 130. In example embodiments, the structural insert 140 may be made of a plastic material or any number of materials that can impart greater performance to the rubber isolation pad 130 in terms of rigidity and shear resistance. In some cases, the structural insert 140 may not be completely surrounded by the rubber isolation pad 130. For example, the structural insert 140 may be disposed above or below the rubber isolation pad 130 relative to the coil spring 110. Additionally, the spring isolation pad may have a substantially different structure than the rubber isolation pad 130. The second plurality of extensions of the structural insert 140 may include extensions that may not match equivalent extensions of the first plurality of extensions of the rubber isolation pad 130.

[0027] In an example embodiment, the structural insert 140 can include a guide member 144 to help position the structural insert 140 relative to the coil spring 110. In some cases, the guide member 144 of the structural insert 140 can be cylindrical, circular, rectangular, pentagonal, hexagonal, octagonal, or any number of shapes that can help position the structural insert 140 relative to the coil spring 110. In an example embodiment, the guide member 144 can extend into an interior region of the coil spring 110 when the coil spring 110 is operably coupled to the guide member 144. The guide member can provide additional support to the coil spring 110 and the suspension assembly 100 as a whole.

[0028] In some cases, the base 145 of the structural insert 140 may include an outer edge 147. The outer edge 147 and the guide member 144 may be operably coupled via a fillet 146. The fillet 146 may help reduce stress peaks experienced by the structural insert 140 by distributing stress over a wider area. In an example embodiment, the fillet 146 radius may gradually increase from the guide member 144 to the outer edge 147. In some cases, the fillet 146 may extend completely around the guide member 144 (360 degrees) and define a gradual change from the vertical extension direction of the guide member 144 to the horizontal extension direction of the outer edge 147. The fillet 146 may extend and be operably coupled completely around the interior of the outer edge 147. In an example embodiment, the outer edge 147 may not extend completely around the fillet 146 and the guide member 144. For example, the outer edge 147 may not extend between the first structural insert extension 141 and the second structural insert extension 142.

[0029] In some cases, the first structural insert extension 141 and the second structural insert extension 142 may be formed by the outer rim 147. In an example embodiment, the first structural insert extension 141 and the second structural insert extension 142 may have an angled structure. For example, the first structural insert extension 141 and the second structural insert extension 142 may have an angled structure of approximately 90 degrees. In some cases, the first structural insert extension 141 and the second structural insert extension 142 may be flat, rounded, or any number of shapes or structures that can support the rubber isolation pad 130 and the coil spring 110. In an example embodiment, the first structural insert extension 141 and the second structural insert extension 142 may be disposed on a radially outer edge 148 of the outer rim 147. In some cases, the first structural insert extension 141 and the second structural insert extension 142 may be disposed on a radially inner edge of the outer rim 147 or on a face of the outer rim 147.

[0030] In an example embodiment, a plurality of holes 143 may be included on the face of the outer edge 147. The plurality of holes 143 may be mounting holes for securing the structural insert 140 to an element within the suspension assembly 100. In some cases, the rubber isolation pad 130 may include a matching plurality of holes 133, which may correspond to the plurality of holes 143. In addition to, but not limited to, the matching plurality of holes 133, the first rubber isolation pad extension 131, and the second rubber isolation pad extension 132, the rubber isolation pad 130 may also include a variety of elements that match the structural insert 140. For example, the rubber isolation pad 130 may include a matching guide member 134 and a matching fillet 136. The matching element of the rubber isolation pad 130 may have a similar structure, but may not have the same shape or structure as the counterpart element of the structural insert 140.

[0031] In some cases, rubber isolation pad 130 may be operably coupled to spring link 125 via a first plurality of extensions in addition to first rubber isolation pad extension 131. For example, lower rubber isolation pad extension 137 and lateral rubber isolation pad extension 138 may operably couple rubber isolation pad 130 to spring link 125. In an example embodiment, first plurality of extensions may include any number of extensions that may help improve performance and durability of suspension assembly 100.

[0032] In an example embodiment, lower rubber isolation pad extension 137 can be disposed at and protrude from a back side of rubber isolation pad 130. In some cases, lower rubber isolation pad extension 137 can operably couple rubber isolation pad 130 and spring link 125 via insertion into a hole in spring link 125. Lower rubber isolation pad extension 137 can be any number of shapes that can help operably couple rubber isolation pad 130 and spring link 125.

[0033] In some cases, a lateral rubber isolation pad extension 138 can be disposed at and protrude from a back side of the rubber isolation pad 130. For example, the lateral rubber isolation pad extension 138 can extend radially from an outer surface located at a peripheral edge of the rubber isolation pad 130. The lateral rubber isolation pad extension 138 can operably couple the rubber isolation pad 130 and the spring link 125 via positioning the lateral rubber isolation pad extension 138 within a groove, space, slot, or notch in the spring link 125. The lateral rubber isolation pad extension 138 can be any number of shapes that can help operably couple the rubber isolation pad 130 and the spring link 125.

[0034] In an example embodiment, the first plurality of extensions of rubber isolation pad 130 may include third rubber isolation pad extension 135 and fourth rubber isolation pad extension 139. Third rubber isolation pad extension 135 and fourth rubber isolation pad extension 139 may help position coil spring 110 relative to rubber isolation pad 130. In some cases, third rubber isolation pad extension 135 may have a concave structure for receiving first coil 111 of coil spring 110 and may be disposed on a base of rubber isolation pad 130. Third rubber isolation pad extension 135 may surround approximately 50% or more of the circumference of first coil 111 of coil spring 110. Third rubber isolation pad extension 135 may be any number of shapes that may receive first coil 111 of coil spring 110 and help position coil spring 110 with rubber isolation pad 130.

[0035] In an example embodiment, a fourth rubber isolation pad extension 139 can be disposed on the mating guide member 134 of the rubber isolation pad 130. The fourth rubber isolation pad extension 139 can extend radially outward from the mating guide member and can be disposed between the first coil 111 and the second coil 112 of the coil spring 110. The fourth rubber isolation pad extension 139 can help position the coil spring 110 with the rubber isolation pad 130. The fourth rubber isolation pad extension 139 can be any number of shapes or structures that can help position the coil spring 110 with the rubber isolation pad 130.

[0036] In some cases, structural insert 140 is a unitary piece. In an example embodiment, rubber isolation pad 130 is a unitary piece. In some cases, rubber isolation pad 130 can be overmolded onto structural insert 140. Rubber isolation pad 130 and structural insert 140 can be manufactured via any number of methods that can produce a durable and consistent product.

[0037] A spring isolation pad for a suspension assembly of a vehicle may therefore be provided. The spring isolation pad may include a rubber isolation pad for supporting a coil spring operably coupled to a control arm, and a structural insert for supporting the coil spring and the rubber isolation pad. The rubber isolation pad may be operably coupled to the structural insert and include a first plurality of extensions. The structural insert may include a second plurality of extensions and a base. The control arm may include a spring link having an orifice. The structural insert may engage with the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle via the first plurality of extensions and the second plurality of extensions.

[0038] The spring isolation pad of the suspension assembly of some embodiments may include additional features, modifications, extensions, etc. to achieve additional goals or enhance the performance of the suspension assembly. The additional features, modifications, extensions, etc. may be added in any combination with each other. The following is a list of various additional features, modifications and extensions, which may be added individually or in any combination with each other. For example, the second plurality of extensions may include a first structural insert extension and a second structural insert extension. The first structural insert extension may protrude from the base of the structural insert parallel to the longitudinal axis of the coil spring in a first direction away from the coil spring, and the second structural insert extension may protrude from the base of the structural insert parallel to the longitudinal axis of the coil spring in a second direction toward the coil spring. In an example embodiment, the first plurality of extensions may include a first rubber isolation pad extension and a second rubber isolation pad extension. The first rubber isolation pad extension may protrude from the rubber isolation pad in a first direction, and the second rubber isolation pad extension may protrude from the rubber isolation pad in a second direction. In some cases, the first structural insert extension and the first rubber isolation pad extension can engage the orifice of the spring link, and the second structural insert extension and the second rubber isolation pad extension can engage the end of the coil spring. In an example embodiment, the first structural insert extension and the first rubber isolation pad extension have free movement within the orifice of the spring link. In some cases, the structural insert may be completely enclosed inside the rubber isolation pad. In an example embodiment, the structural insert may include a guide member, wherein the guide member may be cylindrical and may extend into the inner region of the coil spring. In some cases, the base of the structural insert may include an outer rim having a plurality of holes, and the outer rim and the guide member may be operably coupled via a fillet, and the fillet may extend 360 degrees around the guide member. In an example embodiment, the first structural insert extension and the second structural insert extension may be disposed on the outer edge of the outer rim of the structural insert. In some cases, the structural insert may limit the coil spring from rotating more than 90 degrees from an initial position during operation of the vehicle.

[0039] A suspension assembly for a vehicle of an example embodiment may therefore be provided. The suspension assembly may include: a coil spring disposed beneath a chassis of the vehicle; a control arm operably coupled to the coil spring and a wheel of the vehicle; a rubber isolation pad for supporting the coil spring; and a structural insert for supporting the coil spring and the rubber isolation pad. The control arm may include a spring link having an orifice. The rubber isolation pad may be disposed on the structural insert and include a first plurality of extensions. The structural insert may include a second plurality of extensions and a base. The structural insert may engage the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle via the first plurality of extensions and the second plurality of extensions.

[0040] A person skilled in the art of the invention who has benefited from the teachings presented in the foregoing description and the associated drawings will think of many modifications and other embodiments of the invention set forth herein. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. In addition, although the foregoing description and the associated drawings describe exemplary embodiments in the context of certain exemplary combinations of elements and / or functions, it should be understood that alternative embodiments may provide different combinations of elements and / or functions without departing from the scope of the appended claims. In this regard, for example, as may be set forth in some of the appended claims, combinations of elements and / or functions different from those explicitly described above are also contemplated. Where advantages, benefits, or solutions to problems are described herein, it should be understood that such advantages, benefits, and / or solutions may be applicable to some example embodiments, but not necessarily to all example embodiments. Therefore, any advantages, benefits, or solutions described herein should not be considered to be critical, necessary, or essential to all embodiments or embodiments claimed herein. Although specific terms are employed herein, they are used only in a general and descriptive sense, not for the purpose of limitation.

[0041] According to the present invention, a spring isolation pad for a suspension assembly of a vehicle is provided, which has: a rubber isolation pad, the rubber isolation pad is used to support a coil spring operably connected to a control arm; and a structural insert, the structural insert is used to support the coil spring and the rubber isolation pad, wherein the rubber isolation pad is operably connected to the structural insert and includes a first plurality of extensions, wherein the structural insert includes a second plurality of extensions and a base, wherein the control arm includes a spring link having an orifice, wherein the structural insert engages with the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle via the first plurality of extensions and the second plurality of extensions.

[0042] According to an embodiment, the second plurality of extensions comprises a first structural insert extension and a second structural insert extension, wherein the first structural insert extension protrudes from the base of the structural insert in a first direction away from the coil spring parallel to the longitudinal axis of the coil spring, and wherein the second structural insert extension protrudes from the base of the structural insert in a second direction towards the coil spring parallel to the longitudinal axis of the coil spring.

[0043] According to an embodiment, the first plurality of extensions comprises a first rubber isolation pad extension and a second rubber isolation pad extension, wherein the first rubber isolation pad extension protrudes from the rubber isolation pad in the first direction, and wherein the second rubber isolation pad extension protrudes from the rubber isolation pad in the second direction.

[0044] According to an embodiment, the first structural insert extension and the first rubber spacer extension engage the aperture of the spring link, and wherein the second structural insert extension and the second rubber spacer extension engage an end of the coil spring.

[0045] According to an embodiment, the first structural insert extension and the first rubber isolation pad extension have freedom of movement within the aperture of the spring link.

[0046] According to an embodiment, the structural insert is completely enclosed inside the rubber insulation pad.

[0047] According to an embodiment, the structural insert comprises a guide member, wherein the guide member is cylindrical and extends into an inner region of the helical spring.

[0048] According to an embodiment, the base of the structural insert comprises an outer rim having a plurality of holes, wherein the outer rim and the guide member are operably coupled via a fillet, the fillet extending 360 degrees around the guide member.

[0049] According to an embodiment, the first and second structural insert extensions are arranged on outer edges of the outer rim of the structural insert.

[0050] According to an embodiment, the structural insert limits the coil spring from rotating more than 90 degrees from an initial position during operation of the vehicle.

[0051] According to the present invention, a suspension assembly for a vehicle is provided, comprising: a coil spring disposed under a chassis of the vehicle; a control arm operably connected to the coil spring and a wheel of the vehicle; a rubber isolation pad for supporting the coil spring; and a structural insert for supporting the coil spring and the rubber isolation pad, wherein the control arm comprises a spring link having an aperture, wherein the rubber isolation pad is operably connected to the structural insert and comprises a first plurality of extensions, wherein the structural insert comprises a second plurality of extensions and a base, and wherein the structural insert engages with the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle via the first plurality of extensions and the second plurality of extensions.

[0052] According to an embodiment, the second plurality of extensions comprises a first structural insert extension and a second structural insert extension, wherein the first structural insert extension protrudes from the base of the structural insert in a first direction away from the coil spring parallel to the longitudinal axis of the coil spring, and wherein the second structural insert extension protrudes from the base of the structural insert in a second direction towards the coil spring parallel to the longitudinal axis of the coil spring.

[0053] According to an embodiment, the first plurality of extensions comprises a first rubber isolation pad extension and a second rubber isolation pad extension, wherein the first rubber isolation pad extension protrudes from the rubber isolation pad in the first direction, and wherein the second rubber isolation pad extension protrudes from the rubber isolation pad in the second direction.

[0054] According to an embodiment, the first structural insert extension and the first rubber spacer extension engage the aperture of the spring link, and wherein the second structural insert extension and the second rubber spacer extension engage an end of the coil spring.

[0055] According to an embodiment, the first structural insert extension and the first rubber isolation pad extension have freedom of movement within the aperture of the spring link.

[0056] According to an embodiment, the structural insert is completely enclosed inside the rubber insulation pad.

[0057] According to an embodiment, the structural insert comprises a guide member, wherein the guide member is cylindrical and extends into an inner region of the helical spring.

[0058] According to an embodiment, the base of the structural insert comprises an outer rim having a plurality of holes, wherein the outer rim and the guide member are operably coupled via a fillet extending 360 degrees around the guide member.

[0059] According to an embodiment, the first and second structural insert extensions are arranged on outer edges of the outer rim of the structural insert.

[0060] According to an embodiment, the structural insert limits the coil spring from rotating more than 90 degrees from an initial position during operation of the vehicle.

Claims

1. A spring isolation pad for a suspension assembly of a vehicle, the spring isolation pad comprising: a rubber isolation pad for supporting a coil spring operably coupled to a control arm; as well as a structural insert for supporting the coil spring and the rubber isolation pad, wherein the rubber isolation pad is operably coupled to the structural insert and includes a first plurality of extensions, wherein the structural insert comprises a second plurality of extensions and a base, wherein the control arm includes a spring link having an aperture, Wherein the structural insert engages the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle through the first plurality of extensions and the second plurality of extensions.

2. The spring spacer of claim 1 , wherein the second plurality of extensions comprises a first structural insert extension and a second structural insert extension, wherein the first structural insert extension protrudes from the base of the structural insert parallel to the longitudinal axis of the coil spring in a first direction away from the coil spring, and Wherein the second structural insert extension protrudes from the base of the structural insert in a second direction towards the coil spring parallel to the longitudinal axis of the coil spring.

3. The spring spacer of claim 2, wherein the first plurality of extensions comprises a first rubber spacer extension and a second rubber spacer extension, wherein the first rubber isolation pad extension protrudes from the rubber isolation pad in the first direction, and The second rubber isolation pad extension portion protrudes from the rubber isolation pad in the second direction.

4. The spring spacer of claim 3, wherein the first structural insert extension and the first rubber spacer extension engage the aperture of the spring link, and Wherein the second structural insert extension and the second rubber isolation pad extension engage ends of the coil spring.

5. The spring isolation pad of claim 4, wherein the first structural insert extension and the first rubber isolation pad extension have free movement within the aperture of the spring link.

6. The spring isolation pad of claim 1 wherein said structural insert is completely enclosed within said rubber isolation pad.

7. The spring spacer of claim 1, wherein the structural insert includes a guide member, wherein the guide member is cylindrical and extends into an interior region of the coil spring.

8. The spring spacer of claim 7, wherein the base of the structural insert includes an outer rim having a plurality of holes, wherein the outer rim and the guide member are operably coupled via a fillet, the fillet extending 360 degrees around the guide member, and The first structural insert extension and the second structural insert extension are arranged on the outer edge of the outer edge of the structural insert.

9. The spring isolation pad of claim 1, wherein the structural insert limits the coil spring from rotating more than 90 degrees from an initial position during operation of the vehicle.

10. A suspension assembly for a vehicle, comprising: a coil spring disposed below a chassis of the vehicle; a control arm operably coupled to the coil spring and a wheel of the vehicle; A rubber isolation pad, the rubber isolation pad is used to support the coil spring; as well as a structural insert for supporting the coil spring and the rubber isolation pad, wherein the control arm includes a spring link having an aperture, wherein the rubber isolation pad is operably coupled to the structural insert and includes a first plurality of extensions, wherein the structural insert comprises a second plurality of extensions and a base, and Wherein the structural insert engages the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to a compression cycle through the first plurality of extensions and the second plurality of extensions.

11. The suspension assembly of claim 10, wherein the second plurality of extensions includes a first structural insert extension and a second structural insert extension, wherein the first structural insert extension protrudes from the base of the structural insert parallel to the longitudinal axis of the coil spring in a first direction away from the coil spring, and Wherein the second structural insert extension protrudes from the base of the structural insert in a second direction towards the coil spring parallel to the longitudinal axis of the coil spring.

12. The suspension assembly of claim 11, wherein the first plurality of extensions includes a first rubber isolation pad extension and a second rubber isolation pad extension, wherein the first rubber isolation pad extension protrudes from the rubber isolation pad in the first direction, and wherein the second rubber isolation pad extension portion protrudes from the rubber isolation pad in the second direction, wherein the first structural insert extension and the first rubber isolation pad extension engage the aperture of the spring link, wherein the second structural insert extension and the second rubber isolation pad extension engage ends of the coil spring, and Wherein the first structural insert extension and the first rubber isolation pad extension have free movement within the aperture of the spring link.

13. The suspension assembly of claim 10, wherein the structural insert is completely enclosed within the rubber isolation pad.

14. The suspension assembly of claim 10, wherein the structural insert includes a guide member, wherein the guide member is cylindrical and extends into an interior region of the coil spring, wherein the base of the structural insert includes an outer rim having a plurality of holes, wherein the outer rim and the guide member are operably coupled via a fillet extending 360 degrees around the guide member, and The first structural insert extension and the second structural insert extension are arranged on the outer edge of the outer edge of the structural insert.

15. The suspension assembly of claim 10, wherein the structural insert limits the coil spring from rotating more than 90 degrees from an initial position during operation of the vehicle.

Images