SPRING INSULATION PAD WITH INTEGRATED SPRING TURN STOP AND PAD TURN STOP

Abstract

A spring isolation pad for a suspension assembly for a vehicle may be provided. The spring isolation pad may include a rubber isolation pad for supporting a coil spring operatively coupled to a control arm, and a structural insert for supporting a coil spring and the rubber isolation pad. The rubber isolation pad may be operatively 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 opening. 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 compression cycles across the first plurality of extensions and the second plurality of extensions.

Description

FIELD OF TECHNOLOGY

[0001] Example embodiments relate generally to suspension components and, more particularly, to a spring isolation pad for confining a coil spring and coil spring support members of a strut of a vehicle. GENERAL STATE OF THE ART

[0002] Some vehicles utilize a relatively simple suspension assembly for ease of manufacture. The suspension assembly, in these cases, may include various suspension components, including a coil spring, a control arm, a spring link, a rubber isolation pad, and a spring isolation pad. The spring link, rubber isolation pad, and spring isolation pad may work together to help limit rotation of the coil spring relative to the control arm during compression cycles.

[0003] To prevent and limit the rotation of a coil spring in a suspension assembly, a rubber isolation pad has traditionally been used with the spring link to limit rotation. However, during vehicle operation, the coil spring is subjected to various changes in load and tension, which can cause a subsystem of the suspension assembly to rotate. Rotation of the coil spring can lead to reduced performance. Therefore, there may be a need to add further support to the rubber isolation pad and the suspension assembly without adding new parts that can compromise the efficiency and weight of the suspension assembly and vehicle. BRIEF DESCRIPTION OF SOME EXAMPLES

[0004] According to one embodiment, a spring isolation pad may be provided for a suspension assembly for a vehicle. The spring isolation pad may include a rubber isolation pad for supporting a coil spring operatively coupled to a control arm, and a spring isolation pad for supporting a coil spring and the rubber isolation pad. The rubber isolation pad may be operatively coupled to the spring isolation pad 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 opening. 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 compression cycles across the first plurality of extensions and the second plurality of extensions.

[0005] In another embodiment, a suspension assembly for a vehicle of one embodiment may be provided. The suspension assembly may include a coil spring disposed beneath a chassis of the vehicle, a control arm operatively 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. The control arm may include a spring link having an opening. 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 compression cycles across the first plurality of extensions and the second plurality of extensions. BRIEF DESCRIPTION OF THE DIFFERENT VIEWS OF THE DRAWING(S)

[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: Fig. 1 illustrates a block diagram of a suspension assembly for a vehicle suspension system according to one embodiment; Fig. 2 illustrates a perspective view of a suspension assembly of a vehicle suspension system according to one embodiment; Fig. 3 illustrates a perspective view of a portion of the suspension assembly according to one embodiment; Fig. 4 illustrates a separated view of the spring isolation pad according to one embodiment; Fig. 5 illustrates a cross-sectional side view of the spring isolation pad according to one embodiment; Fig. 6 illustrates a perspective view of the structural insert according to one embodiment; Fig. 7 illustrates a plan view of the structural insert according to one embodiment; Fig. 8 illustrates a perspective view of the rubber isolation pad according to one embodiment; Fig. 9 illustrates a side view of the rubber isolation pad according to an embodiment; and Fig. 10 illustrates a bottom view of the rubber isolation pad according to one embodiment. DETAILED DESCRIPTION

[0007] Some embodiments will now be described in more detail below with reference to the accompanying drawings, in which some, but not all, of the embodiments are illustrated. Indeed, the examples described and illustrated in this specification should not be construed as limiting the scope, applicability, or configuration of the present disclosure. Rather, these embodiments are provided so that this disclosure will satisfy applicable requirements. Like reference numerals refer to like elements throughout. Furthermore, the term "or," as used in this specification, should be interpreted as a logical operator that evaluates to true when one or more of its operands are true.As used in this document, active coupling is understood to mean a direct or indirect connection which in any case enables a functional connection of components which are actively coupled to one another.

[0008] Some embodiments described herein may address the problems described above. In this regard, for example, some embodiments may provide a structural insert for a vehicle's suspension system, making the coil spring and the suspension system as a whole stronger and more efficient. Some embodiments may provide for the structural insert to be a single piece enclosed by the rubber isolation pad. As a result, installation of the suspension assembly may require less effort, fewer components, and less time, and may thus be more efficient.

[0009] Fig. 1 illustrates a block diagram of the suspension assembly 100 of a vehicle 10 according to one embodiment, and Fig. 2 illustrates a perspective view of a suspension assembly for a vehicle suspension system according to one embodiment. As shown in the Fig. 1-2, 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 operatively coupled to a body 20 and a wheel 30 of a vehicle. In some cases, the vehicle 10 may include a chassis or frame. The chassis or frame may support and form the basic structure of the vehicle 10. In one embodiment, the chassis and frame may be formed from one or more molded subframes, and the coil spring 110 may be operatively coupled to the chassis or frame. In some cases, the vehicle may have a unibody design, with the chassis / frame and the body 20 being one member.In some cases, the coil spring 110 may be part of a strut system of the vehicle. In this regard, the coil spring 110 may dampen the articulation of the wheel 30 so that the movement of the wheel 30 cannot be directly translated into movement of the body 20. In this way, the coil spring 110 may improve the ride quality as perceived by passengers within the body 20 of the vehicle 10 by absorbing some of the force from bumps due to the articulation of the wheel 30. Additionally, in one embodiment, the suspension assembly 100 may take the form of a strut structure, and in this regard, the suspension assembly 100 may also play a role in steering the vehicle 10. Therefore, the coil spring 110 may be operatively coupled to a control arm 120, and the control arm 120 may act as a steering pivot for the wheel 30.The control arm 120 may be operatively coupled to the wheel 30 on one side and to the chassis, frame, or body 20 on another side. Regardless, the coil spring 110 may, in some cases, have a substantially helical shape.

[0010] 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 serve to operatively couple the control arm 120 and the coil spring 110. The spring link 125 may be operatively coupled to the coil spring 110 via the rubber isolation pad 130 and the 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 operatively couple the elements of the suspension assembly 100. Together, the spring link 125, the rubber isolation pad 130, and the structural insert 140, through their structure and orientation, may help limit the rotation of the coil spring 110.The coil spring 110 may tend to rotate clockwise relative to the front of the vehicle 10 when under load and tension from the operation of the vehicle 10, causing the coil spring 110 to compress. In some cases, the coil spring 110 may tend to rotate counterclockwise under compression. The rotational force of the coil spring 110 may cause forces to be focused on various elements of the suspension assembly 100. Thus, the provided support and operative coupling of the spring link 125, the rubber isolation pad 130, and the structural insert 140 may help balance the resulting forces transmitted by the coil spring 110 and increase the durability of the suspension assembly 100.

[0011] Fig. 3 illustrates a perspective view of a portion of the suspension assembly 100 according to one embodiment, and Fig. 4 illustrates a separated view of the spring isolation pad 150 according to one embodiment. In this regard, Fig. 3 illustrates the engagement between the spring connector 125, the rubber isolation pad 130, and the structural insert 140 according to one embodiment. In some cases, the rubber isolation pad 130 may completely enclose the structural insert 140. In other words, the rubber isolation pad 130 may be a type of housing or cover for the structural insert 140 that may extend completely around and enclose the structural insert 140. The structural insert 140 may therefore be an underlying structure that can help support the rubber isolation pad 130 to increase 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 may be formed of a rigid material, such as a metal alloy, to provide the strength to support the shape of the rubber isolation pad 130 in its operative coupling with the coil spring 110.

[0012] As in Fig. 4, the structure of the rubber isolation pad 130 and the structural insert 140 may be similar to each other. The rubber isolation pad 130 may include a first plurality of extensions that engage the coil spring 110 and the spring connecting member 125. The structural insert 140 may have a second plurality of extensions that engage the coil spring 110 and the spring connecting member 125 as well as engage the first plurality of extensions. The second plurality of extensions of the structural insert 140 may include a first structural insert extension 141 and a second structural insert extension 142. The first structural insert extension 141 may protrude from a base 145 of the structural insert 140 substantially parallel to a longitudinal axis of the coil spring 110 in a first direction away from the coil spring 110.The second structural insert extension 142 may protrude from a base 145 of the structural insert 140 substantially parallel to a longitudinal axis of the coil spring 110 in a second direction toward the coil spring 110. The first rubber isolation pad extension 131 may protrude from the rubber isolation pad 130 in the first direction, and the second rubber isolation pad extension 132 may protrude from the rubber isolation pad 130 in the second direction. In some cases, because the rubber isolation pad 130 completely encloses the structural insert 140, the first plurality of extensions and the second plurality of extensions may serve similar functional purposes for limiting rotation of the coil spring 110 during operation of the vehicle 10.

[0013] As in the Fig. 2-3, the first structural insert extension 141 and the first rubber isolation pad extension 131 may engage an opening 126 of the spring link 125. The opening 126 may be a drain hole for removing 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 isolation pad extension 132 may engage an end of the coil spring 110. Because the coil spring 110 may be urged to rotate in response to compression cycles, the end of the coil spring 110 may press against the second structural insert extension 142 and the second rubber isolation pad extension 132 and may thus exert a force on the rubber isolation pad 130 and the structural insert 140.As a result, however, the first structural insert extension 141 and the first rubber isolation pad extension 131 may operatively couple to the opening 126 of the spring link 125, which may limit the rotation of the coil spring 110. In one embodiment, the first structural insert extension 141 and the first rubber isolation pad extension 131 may move freely within the opening 126 of the spring link 125 when maximum tension is not reached. The size of the opening 126 of the spring link may help limit the maximum degree of rotation of the coil spring 110. In some cases, the coil spring 110 may be limited to 90 degrees of rotation.

[0014] In one embodiment, the second rubber isolation pad extension 132 may be a concave structure that can accommodate the end of the coil spring 110. The second rubber isolation pad extension 132 may completely surround the end of the coil spring 110. In some cases, the second rubber isolation pad extension 132 may taper the further the second rubber isolation pad extension 132 protrudes from the rubber isolation pad 130. In one embodiment, the second rubber isolation pad extension 132 may have any structure or shape that can help secure and position the end of the coil spring 110 to the rubber isolation pad 130.

[0015] Fig. 5-10 illustrate different views of the rubber isolation pad 130 and the structural insert 140 alone and in combination with each other. Fig. 5 illustrates a cross-sectional view of the spring isolation pad 150 according to one embodiment. As in Fig.5, the rubber isolation pad 130 may be continuously supported by the structural insert 140 disposed therein. For example, the first rubber isolation pad extension 131 may be supported by the first structural insert extension 141, and the second rubber isolation pad extension 132 may be supported by the second structural insert extension 142. In some cases, the rubber isolation pad 130 may be made of rubber, polymer, or any other material to ensure an elastomeric property of the rubber isolation pad 130. In one embodiment, the rubber isolation pad 130 may be non-elastomeric and may be made of any number of materials to ensure performance and durability for the coil spring 110 and the suspension assembly 100 as a whole. In one embodiment, the rubber isolation pad 130 may serve as a damper for the suspension assembly 100.

[0016] 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 one embodiment, the structural insert 140 may be made of a plastic material or any number of materials that can provide the rubber isolation pad 130 with greater performance in terms of stiffness and resistance to shear forces. In some cases, the structural insert 140 may not be completely enclosed 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 isolator 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 mate with an equivalent extension of the first plurality of extensions of the rubber isolation pad 130.

[0017] In one embodiment, the structural insert 140 may include a guide member 144 to assist in positioning the structural insert 140 relative to the coil spring 110. In some cases, the guide member 144 of the structural insert 140 may be cylindrical, circular, rectangular, pentagonal, hexagonal, octagonal, or any number of shapes that may assist in positioning the structural insert 140 relative to the coil spring 110. In one embodiment, the guide member 144 may extend into an interior region of the coil spring 110 when the coil spring 110 is operatively coupled to the guide member 144. The guide member may provide additional support to the coil spring 110 and the suspension assembly 100 as a whole.

[0018] 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 operatively coupled via a fillet 146. The fillet 146 may help reduce stress peaks experienced by the structural insert 140 by distributing the stress over a wider area. In one embodiment, the radius of the fillet 146 may gradually increase from the guide member 144 to the outer edge 147. In some cases, the fillet 146 may extend completely (360 degrees) around the guide member 144, defining a gradual change in direction from a vertical extension direction of the guide member 144 to a horizontal extension direction of the outer edge 147. The fillet 146 may extend completely around an interior of the outer edge 147 and be operatively coupled.In one embodiment, the outer edge 147 may not extend completely around the groove 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.

[0019] In some cases, the first structural insert extension 141 and the second structural insert extension 142 may be formed from the outer edge 147. In one 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 approximately a 90-degree angled structure. 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 one embodiment, the first structural insert extension 141 and the second structural insert extension 142 may be disposed at a radially outer edge 148 of the outer edge 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 surface of the outer rim 147.

[0020] In one embodiment, a plurality of openings 143 may be included on a surface of the outer edge 147. The plurality of openings 143 may be mounting openings for attaching the structural insert 140 to elements within the suspension assembly 100. In some cases, the rubber isolation pad 130 may include a mating plurality of openings 133 that may correspond to the plurality of openings 143. The rubber isolation pad 130 may include, but is not limited to, a variety of mating elements for the structural insert 140 in addition to the mating plurality of openings 133, the first rubber isolation pad extension 131, and the second rubber isolation pad extension 132. For example, the rubber isolation pad 130 may include a mating guide member 134 and a mating groove 136.Mating elements of the rubber isolation pad 130 may have a similar structure, but may not have an identical shape or structure to the mating elements of the structural insert 140.

[0021] In some cases, the rubber isolation pad 130 may be operatively coupled to the spring link 125 via the first plurality of extensions other than the first rubber isolation pad extension 131. For example, the lower rubber isolation pad extension 137 and the side rubber isolation pad extension 138 may operatively couple the rubber isolation pad 130 to the spring link 125. In one embodiment, the first plurality of extensions may include any number of extensions that may help increase the performance and durability of the suspension assembly 100.

[0022] In one embodiment, the lower rubber isolation pad extension 137 may be disposed on and protrude from a rear surface of the rubber isolation pad 130. In some cases, the lower rubber isolation pad extension 137 may operatively couple the rubber isolation pad 130 and the spring connector 125 via insertion into an opening in the spring connector 125. The lower rubber isolation pad extension 137 may have any number of shapes that may assist in operatively coupling the rubber isolation pad 130 and the spring connector 125.

[0023] In some cases, side rubber isolation pad extension 138 may be disposed on and protrude from an outer surface of the rubber isolation pad 130. For example, the side rubber isolation pad extension 138 may extend radially from an outer surface located at a peripheral edge of the rubber isolation pad 130. The side rubber isolation pad extension 138 may operatively couple the rubber isolation pad 130 and the spring connector 125 via positioning the side rubber isolation pad extensions 138 within a groove, space, slot, or notch in the spring connector 125. The side rubber isolation pad extension 138 may have any number of shapes that may assist in operatively coupling the rubber isolation pad 130 and the spring connector 125.

[0024] In one embodiment, the first plurality of extensions of the rubber isolation pad 130 may include a third rubber isolation pad extension 135 and a fourth rubber isolation pad extension 139. The third rubber isolation pad extension 135 and the fourth rubber isolation pad extension 139 may assist in positioning the coil spring 110 relative to the rubber isolation pad 130. In some cases, the third rubber isolation pad extension 135 may have a concave structure for receiving a first coil 111 of the coil spring 110 and may be disposed on a base of the rubber isolation pad 130. The third rubber isolation pad extension 135 may enclose approximately 50% or more of the circumference of a first coil 111 of the coil spring 110.The third rubber isolation pad extension 135 may have any number of shapes that can accommodate the first turn 111 of the coil spring 110 and help position the coil spring 110 on the rubber isolation pad 130.

[0025] In one embodiment, the fourth rubber isolation pad extension 139 may be disposed on the mating guide member 134 of the rubber isolation pad 130. The fourth rubber isolation pad extension 139 may extend radially outward from the mating guide member and may be disposed between the first coil 111 and a second coil 112 of the coil spring 110. The fourth rubber isolation pad extension 139 may assist in positioning the coil spring 110 on the rubber isolation pad 130. The fourth rubber isolation pad extension 139 may be any number of shapes or structures that may assist in positioning the coil spring 110 on the rubber isolation pad 130.

[0026] In some cases, the structural insert 140 is a single piece. In one embodiment, the rubber isolation pad 130 is a single piece. In some cases, the rubber isolation pad 130 may be overmolded onto the structural insert 140. The rubber isolation pad 130 and the structural insert 140 may be manufactured by any number of processes that can produce a durable and consistent product.

[0027] A spring isolation pad for a suspension assembly for a vehicle may therefore be provided. The spring isolation pad may include a rubber isolation pad for supporting a coil spring operatively coupled to a control arm, and a structural insert for supporting a coil spring and the rubber isolation pad. The rubber isolation pad may be operatively 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 opening. 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 compression cycles across the first plurality of extensions and the second plurality of extensions.

[0028] In some embodiments, the spring isolation pad of the suspension assembly may include additional features, modifications, enhancements, and / or the like to accomplish further tasks or improve the performance of the suspension assembly. The additional features, modifications, enhancements, and / or the like may be added in any combination with one another. The following is a list of various additional features, modifications, and enhancements, each of which may be added individually or in any combination with one another. For example, the second plurality of enhancements may include a first structural insert enhancement and a second structural insert enhancement.The first structural insert extension may protrude from a base of the structural insert parallel to a longitudinal axis of the coil spring in a first direction away from the coil spring, and the second structural insert extension may protrude from a base of the structural insert parallel to the longitudinal axis of the coil spring in a second direction toward the coil spring. In one 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 the first direction, and the second rubber isolation pad extension may protrude from the rubber isolation pad in the second direction.In some cases, the first structural insert extension and the first rubber isolation pad extension may engage the opening of the spring connector, and the second structural insert extension and the second rubber isolation pad extension may engage an end of the coil spring. In one embodiment, the first structural insert extension and the first rubber isolation pad extension may move freely within the opening of the spring connector. In some cases, the structural insert may be completely enclosed by the rubber isolation pad. In one embodiment, the structural insert may include a guide member, wherein the guide member may be cylindrical and may extend into an interior region of the coil spring.In some cases, the base of the structural insert may include an outer rim with a plurality of openings, and the outer rim and the guide member may be operatively coupled via a flute that may extend 360 degrees around the guide member. In one embodiment, the first structural insert extension and the second structural insert extension may be disposed at an outer edge of the outer rim of the structural insert. In some cases, the structural insert may limit rotation of the coil spring during operation of the vehicle by more than 90 degrees from an initial position.

[0029] A suspension assembly for a vehicle of one embodiment may therefore be provided. The suspension assembly may include a coil spring disposed beneath a chassis of the vehicle, a control arm operatively 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. The control arm may include a spring link having an opening. 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 compression cycles across the first plurality of extensions and the second plurality of extensions.

[0030] Many modifications and other embodiments of the inventions set forth herein will become apparent to those skilled in the art to which these inventions belong in light of the teachings presented in the foregoing descriptions and the accompanying drawings. Therefore, it is to be understood that the disclosure is not limited to the particular implementations disclosed, and that modifications and other implementations are intended to be included within the scope of the appended claims. Moreover, it is to be understood that, although the foregoing descriptions and the accompanying drawings describe embodiments in terms of certain exemplary combinations of elements and / or functions, different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims.In this regard, other combinations of elements and / or functions than those expressly described above are also contemplated, for example, as may be set forth in some of the appended claims. Where advantages, benefits, or solutions to problems are described herein, it is to be understood that such advantages, benefits, and / or solutions may be applicable to some embodiments, but not necessarily to all embodiments. Thus, any advantages, benefits, or solutions described herein should not be considered critical, required, or essential to all embodiments or to what is claimed herein. Although specific terms are employed in this specification, they are used only in their generic and descriptive sense and not for purposes of limitation.

[0031] According to the present invention, there is provided a spring isolation pad for a suspension assembly for a vehicle, comprising: a rubber isolation pad for supporting a coil spring operatively coupled to a control arm; and a structural insert for supporting a coil spring and the rubber isolation pad, the rubber isolation pad being operatively coupled to the structural member and comprising a first plurality of extensions, the structural insert comprising a second plurality of extensions and a base, the control arm comprising a spring connecting member having an opening, the structural insert engaging the rubber isolation pad and the spring connecting member to limit rotation of the coil spring relative to the control arm in response to compression cycles across the first plurality of extensions and the second plurality of extensions.

[0032] According to one 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 parallel to a 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 parallel to the longitudinal axis of the coil spring in a second direction towards the coil spring.

[0033] According to one 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 protrudes from the rubber isolation pad extension in the second direction.

[0034] According to one embodiment, the first structural insert extension and the first rubber isolation pad extension engage the opening of the spring connecting member, and wherein the second structural insert extension and the second rubber isolation pad extension engage one end of the coil spring.

[0035] According to one embodiment, the first structural insert extension and the first rubber isolation pad extension can move freely in the opening of the spring connecting member.

[0036] According to one embodiment, the structural insert is completely enclosed by the rubber insulation pad.

[0037] According to one embodiment, the structural insert comprises a guide element, wherein the guide element is cylindrical and extends into an inner region of the coil spring.

[0038] According to one embodiment, the base of the structural insert comprises an outer edge having a plurality of openings, wherein the outer edge and the guide element are operatively coupled via a groove extending 360 degrees around the guide element.

[0039] According to one embodiment, the first structural insert extension and the second structural insert extension are arranged on an outer edge of the outer periphery of the structural insert.

[0040] According to one embodiment, the structural insert limits rotation of the coil spring during operation of the vehicle by more than 90 degrees from an initial position.

[0041] According to the present invention, there is provided a suspension assembly for a vehicle, comprising: a coil spring disposed under a chassis of the vehicle; a control arm operatively 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, wherein the control arm includes a spring connecting member having an opening, wherein the rubber isolation pad is operatively coupled to the structural insert and includes a first plurality of extensions, wherein the structural insert includes a second plurality of extensions and a base, and wherein the structural insert engages the rubber isolation pad and the spring connecting member to limit rotation of the coil spring relative to the control arm in response to compression cycles across the first plurality of extensions and the second plurality of extensions.;

[0042] According to one 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 parallel to a 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 parallel to the longitudinal axis of the coil spring in a second direction towards the coil spring.

[0043] According to one 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 protrudes from the rubber isolation pad extension in the second direction.

[0044] According to one embodiment, the first structural insert extension and the first rubber isolation pad extension engage the opening of the spring connecting member, and wherein the second structural insert extension and the second rubber isolation pad extension engage one end of the coil spring.

[0045] According to one embodiment, the first structural insert extension and the first rubber isolation pad extension can move freely in the opening of the spring connecting member.

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

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

[0048] According to one embodiment, the base of the structural insert comprises an outer edge having a plurality of openings, wherein the outer edge and the guide element are operatively coupled via a groove extending 360 degrees around the guide element.

[0049] According to one embodiment, the first structural insert extension and the second structural insert extension are arranged on an outer edge of the outer periphery of the structural insert.

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

Claims

A spring isolation pad for a suspension assembly for a vehicle, the spring isolation pad comprising: a rubber isolation pad for supporting a coil spring operatively coupled to a control arm; and a structural insert for supporting a coil spring and the rubber isolation pad, the rubber isolation pad being operatively coupled to the structural insert and including a first plurality of extensions, the structural insert including a second plurality of extensions and a base, the control arm including a spring link having an opening, the structural insert engaging the rubber isolation pad and the spring link to limit rotation of the coil spring relative to the control arm in response to compression cycles across the first plurality of extensions and the second plurality of extensions. The spring isolation pad 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 a 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 parallel to the longitudinal axis of the coil spring in a second direction toward the coil spring. The spring isolation pad of claim 2, wherein 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. The spring isolation pad of claim 3, wherein the first structural insert extension and the first rubber isolation pad extension engage the opening of the spring connector, and wherein the second structural insert extension and the second rubber isolation pad extension engage an end of the coil spring. The spring isolation pad of claim 4, wherein the first structural insert extension and the first rubber isolation pad extension move freely within the opening of the spring connector. Spring isolation pad according to claim 1, wherein the structural insert is completely enclosed within the rubber isolation pad. The spring isolation pad of claim 1, wherein the structural insert comprises a guide member, the guide member being cylindrical and extending into an interior region of the coil spring. The spring isolation pad of claim 7, wherein the base of the structural insert includes an outer rim having a plurality of openings, wherein the outer rim and the guide member are operatively coupled via a groove extending 360 degrees around the guide member, and wherein the first structural insert extension and the second structural insert extension are disposed at an outer edge of the outer rim of the structural insert. The spring isolation pad of claim 1, wherein the structural insert limits rotation of the coil spring during operation of the vehicle by more than 90 degrees from an initial position. A suspension assembly for a vehicle, comprising: a coil spring disposed beneath a chassis of the vehicle; a control arm operatively 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 includes a spring connecting member having an opening. The rubber isolation pad is operatively coupled to the structural insert and includes a first plurality of extensions. The structural insert includes a second plurality of extensions and a base. The structural insert engages the rubber isolation pad and the spring connecting member to limit rotation of the coil spring relative to the control arm in response to compression cycles across the first plurality of extensions and the second plurality of extensions. The suspension assembly of claim 10, 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 a 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 parallel to the longitudinal axis of the coil spring in a second direction toward the coil spring. The suspension assembly of claim 11, wherein the first plurality of extensions comprises a first rubber isolation pad extension and a second rubber isolation pad extension, the first rubber isolation pad extension protruding from the rubber isolation pad in the first direction, and the second rubber isolation pad extension protruding from the rubber isolation pad in the second direction, the first structural insert extension and the first rubber isolation pad extension engaging the opening of the spring link, the second structural insert extension and the second rubber isolation pad extension engaging an end of the coil spring, and the first structural insert extension and the first rubber isolation pad extension moving freely within the opening of the spring link. The suspension assembly of claim 10, wherein the structural insert is completely enclosed by the rubber isolation pad. The suspension assembly of claim 10, wherein the structural insert comprises a guide member, the guide member being cylindrical and extending into an interior region of the coil spring, the base of the structural insert comprising an outer rim having a plurality of openings, the outer rim and the guide member being operatively coupled via a fillet extending 360 degrees around the guide member, the first structural insert extension and the second structural insert extension being disposed at an outer edge of the outer rim of the structural insert. The suspension assembly of claim 10, wherein the structural insert limits rotation of the coil spring during operation of the vehicle by more than 90 degrees from an initial position.

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