Dual Volume Air Spring

Abstract

A dual volume air spring assembly (300) for a vehicle is disclosed, the air spring assembly (300) comprising a first member (310), a second member (350), and a deflectable diaphragm (360) configured to at least partially define a primary air volume (370) and at least partially define a secondary air volume (380). The deflectable diaphragm (360) is deflected from a first position to a second position due to a change in air pressure differential between the primary air volume (370) and the secondary air volume (380). In one aspect, the air spring assembly (300) comprises a flexible wall member (320) configured with the primary air volume (370). In another aspect, the air spring assembly comprises a damper (400) configured coaxially with the assembly (300). In another embodiment, the air spring assembly (300) includes a piston spring (500) configured with a primary air volume (370). The air spring assembly (300) together with the piston spring (500) provide stability, load bearing spring action, and shock absorption.

Description

[Technical field]

[0001] This disclosure relates generally to the field of air springs. In particular, this disclosure relates to a dual volume air spring assembly and system for supporting loads and isolating vibration and shock where spring action is required, such as in vehicles, machine foundations, buildings, etc. Additionally, this disclosure relates to a method for adjusting the spring rate of an air spring assembly. [Background technology]

[0002] Various types of mechanical springs, such as coil springs, leaf springs, and links, are primarily used in vehicles to isolate vehicle passengers and cargo from undesirable forces due to road undulations, bumps, potholes, etc. However, air springs are used in luxury vehicles to provide a smoother ride. Air springs provide an optimum spring constant only for a specific load and a specific suspension height combination. Known air springs do not provide an optimum spring constant for various combinations of different loads and suspension heights. It is desirable to set an optimum spring constant for each suspension load and height combination to improve ride quality, comfort, handling, and safety.

[0003] Airbags are commonly used as air springs in automobiles, but when the suspension height is low, the spring constant required is less but the spring constant of the airbag is higher, and when the suspension height is high, the spring constant required is higher but the spring constant of the airbag is less. Therefore, there is a need for air spring assemblies and systems that provide the desired value of spring constant for various conditions and loads. Furthermore, a disadvantage of such airbags is that they are inefficient in dealing with forces as they undergo large deflections during cornering, braking, and acceleration, which affects the safety of the vehicle. Also, the demands of airbags to perform optimally under different loading conditions, road conditions, and air suspension heights are not met.

[0004] US Pat. No. 5,399,633 discloses a dual volume air spring for truck suspensions that includes an airbag chamber providing a variable volume and a fixed volume chamber. Both chambers are interconnected by a closable orifice. The airbag is provided with a strut-like orifice closer that is pushed into the orifice when the airbag is fully compressed and pulled out of the orifice when the airbag is not compressed. During normal operation, the orifice is open and the combined volume of both chambers is available, resulting in a low spring constant. The orifice closer has a relatively collapsible orifice closing portion and a rigid or semi-rigid portion that functions as a bump stop when the collapsible portion is substantially fully compressed. When the orifice is fully closed, the spring has a high spring constant.

[0005] Another US Pat. No. 5,399,633 discloses an air spring assembly including a primary air bag attached to a piston air bag, the piston air bag providing a rolling surface for the primary air bag. As the pressure in the piston air bag changes, the effective constant of the primary air spring changes. Relatively small changes in the volume of the piston air bag selectively alter the diameter of the roll-off surface, thereby changing the spring constant of the air spring assembly.

[0006] Both patents disclose different types of air spring assemblies that provide an optimum spring rate for a particular load and a particular suspension height, but do not provide an optimum spring rate for various combinations of different loads and suspension heights, and neither patent teaches that the arrangements disclosed can provide an optimum spring rate for various combinations of different loads and suspension heights to provide control, stability, safety, and comfort for the vehicle occupants. Although U.S. Patent No. 5,233,633 attempts to achieve this goal, it is very difficult to predict and control the diameter of a piston airbag, and therefore the spring rate during the compression and expansion cycles. Also, the air spring assembly is not durable due to the roll-off surface.

[0007] Therefore, there is a need to provide a simple, durable and cost-effective solution that can overcome the above-mentioned challenges of conventional air spring assemblies, by providing an optimal spring rate for various combinations of different loads and suspension heights to ensure vehicle control, stability, safety and passenger comfort. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] U.S. Patent No. 76386525 [Patent Document 2] U.S. Patent No. 7,156,382 Summary of the Invention [Problem to be solved by the invention]

[0009] A general object of the present disclosure is to provide an air spring assembly that can provide different spring rates for different combinations of load conditions, road conditions, and suspension heights.

[0010] The objective of the present disclosure is to provide a solution that is simple, durable and cost-effective.

[0011] Another object of the present disclosure is to provide greater control, safety, and comfort to passengers within a vehicle.

[0012] Another object of the present disclosure is to provide an air spring assembly in which a damper unit can be mounted coaxially.

[0013] Another objective of the present disclosure is to provide a lightweight, efficient air spring assembly and system that can be easily installed in a vehicle.

[0014] Another object of the present disclosure is to provide an air spring assembly. At least one Spring constant Spring properties including To provide a simple and efficient method for adjusting [Means for solving the problem]

[0015] Aspects of the present disclosure relate generally to the field of air springs, and more particularly to dual volume air spring assemblies and systems that support loads and provide vibration and shock isolation where spring action is required, such as in vehicles, machine foundations, buildings, etc. Additionally, the present disclosure relates to a method for adjusting the spring rate of an air spring assembly.

[0016] In one aspect, the disclosure discloses an air spring assembly for a vehicle. The air spring assembly includes a first member at one end and a second member at an opposite end. The air spring assembly further includes a deflectable diaphragm configured to at least partially define a primary air volume and at least partially define a secondary air volume. The primary air volume is provided with a first inlet for filling the primary air volume and the secondary air volume is provided with a second inlet for filling the secondary air volume. The deflectable diaphragm separates the primary air volume and the secondary air volume such that a change in air pressure differential between the primary air volume and the secondary air volume causes deflection of the deflectable diaphragm.

[0017] In one aspect, the air spring assembly includes a damper unit integral with the primary air volume and remaining at least partially within the air spring assembly, a first end of the damper unit configured to be coupled to one portion of the vehicle with a first member and a second end of the damper unit configured to be coupled to another portion of the vehicle with a second member, and wherein a piston rod associated with the damper unit moves correspondingly with the air spring assembly from an extended position to a compressed position when the vehicle is loaded.

[0018] In another aspect, an air spring assembly includes a damper unit integral with the primary air volume and remaining entirely within the air spring assembly, a first end of the damper unit configured to be coupled to one portion of the vehicle with a first member and a second end of the damper unit configured to be coupled to another portion of the vehicle with a second member, and wherein a piston rod associated with the damper unit moves correspondingly with the air spring assembly from an extended position to a compressed position when the vehicle is loaded.

[0019] In one embodiment, the primary air volume is defined by an inner surface of the first member and an inner surface of the second member, an inner surface of the flexible wall member, and an inner surface of the biased diaphragm.

[0020] In one embodiment, the secondary air volume is defined by an inner surface of the first member and an outer surface of the deflectable diaphragm.

[0021] In one embodiment, the deflectable diaphragm remains in a first position when the air pressures in the primary and secondary air chambers are equal, and the deflectable diaphragm deflects to one or more second positions when there is a change in the air pressure differential between the primary and secondary air chambers.

[0022] In one aspect, the air spring assembly includes a plurality of sensors integral with the air spring assembly to monitor one or more operating parameters of the air spring assembly and correspondingly transmit the monitored operating parameters to an electronic control of the vehicle.

[0023] In another aspect, the present disclosure discloses an air spring assembly for a vehicle. The air spring assembly includes a first member at one end and a second member at an opposite end. The air spring assembly further includes a primary air volume and a secondary air volume. The piston spring is configured to be attached to a portion of the vehicle by a support and includes a cylinder and a piston rod configured to be movable within the piston and hermetically sealed to the cylinder by a seal member. The cylinder includes at least one passage for allowing air flow between the cylinder and the primary air volume. The air spring assembly further includes a deflectable diaphragm configured to at least partially define the primary air volume and to at least partially define the secondary air volume. The primary air volume is provided with a first passage for an air inlet and an outlet, and the secondary air volume is provided with a second passage for an air inlet and an outlet. A change in air pressure differential between the primary air volume and the secondary air volume causes deflection of the deflectable diaphragm. The piston rod moves from an extended position to a compressed position and the biasing diaphragm is biased from a first position to a second position due to a change in air pressure differential between the primary air volume and the secondary air volume.

[0024] In one embodiment, at least one flexible wall member defines at least a portion of the primary air volume.

[0025] In one aspect, the at least one piston spring defines at least a portion of the primary air volume, and at least one passageway in an air cylinder of the piston spring fluidly connects the cylinder to the primary air volume.

[0026] In another aspect, the present disclosure discloses an air spring system comprising at least one air spring assembly and a plurality of vehicle sensors configured to measure a plurality of vehicle characteristics and responsively generate a plurality of sensor signals providing information on one or more of the vehicle characteristics including, but not limited to, vehicle load, suspension height, cornering, braking, acceleration, yaw rate, turning, etc. The air spring assembly further comprises a valve assembly configured to control a supply of air into and out of the at least one air spring assembly, and a controller operably coupled to the plurality of sensors and the valve assembly. The controller is configured to receive the plurality of sensor signals from the plurality of vehicle sensors, analyze the received sensor signals to determine desired spring characteristics including at least a spring constant for the vehicle, and generate an output signal to actuate the valve assembly to alter at least one of a pressure and a volume in at least one of a primary air volume chamber and a secondary air volume chamber to achieve the desired spring characteristics for the vehicle.

[0027] In yet another aspect, the present disclosure provides an air spring assembly. At least one Spring constant Spring properties including A method of adjusting an air spring pressure in an air spring assembly is disclosed. The method includes providing a primary air volume adjacent to a secondary air volume with a deflectable diaphragm at least partially defining the primary air volume and at least partially defining the secondary air volume. The method includes providing a primary air volume adjacent to a secondary air volume of an air spring assembly. At least one Spring constant Spring properties including The method further includes the step of varying the pressure or volume in either or a combination of the primary and secondary air volumes to vary the pressure or volume in the primary and secondary air volumes.

[0028] Various objects, features, aspects and advantages of the present subject matter will become more apparent from the following detailed description of preferred embodiments, taken in conjunction with the accompanying drawing figures in which like reference characters represent like elements. Effect of the Invention

[0029] The present disclosure provides an air spring assembly that can provide different spring rates for different combinations of load conditions, road conditions, and suspension heights.

[0030] The present disclosure provides a simple, durable and cost-effective solution.

[0031] The present disclosure provides greater control, safety, and comfort for passengers within a vehicle.

[0032] The present disclosure provides an air spring assembly that can be coaxially equipped with a damper unit.

[0033] The present disclosure provides a lightweight and efficient air spring assembly and system that can be easily implemented into a vehicle.

[0034] The present disclosure provides a simple and efficient method for adjusting the spring rate of an air spring assembly.

[0035] The present disclosure provides a quicker response to a semi-active / active suspension system. [Brief description of the drawings]

[0036] [Figure 1] FIG. 1 illustrates an exemplary cross-sectional view of a dual volume air spring assembly according to a first embodiment as proposed by an embodiment of the present disclosure. [Diagram 2] FIG. 2 is an exemplary cross-sectional and side elevation view of the proposed air spring assembly of FIG. [Diagram 3] FIG. 3 illustrates an exemplary cross-sectional view of the proposed air spring assembly with a damper unit partially inside the air spring assembly, according to an embodiment of the present disclosure. [Figure 4] FIG. 4 illustrates an exemplary cross-sectional view of the disclosed air spring assembly with a damper unit entirely inside the air spring assembly, in accordance with an embodiment of the present disclosure. [Diagram 5]FIG. 5 illustrates an exemplary cross-sectional view of the proposed air spring assembly according to a second embodiment having a piston spring, according to an embodiment of the present disclosure. [Figure 6] FIG. 6 is a diagram illustrating exemplary steps involved in a method for adjusting the spring rate of an air spring assembly according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure, and together with the description, serve to explain the principles of the disclosure.

[0038] The following is a detailed description of the embodiments of the present disclosure, as illustrated in the accompanying drawings. The embodiments are described in detail to clearly convey the disclosure. However, the amount of detail provided is not intended to limit the anticipated variations of the embodiments, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0039] FIELD OF THE DISCLOSURE The embodiments described herein relate generally to the field of air spring systems, and more particularly to dual volume air spring assemblies and systems that provide load support and vibration and shock isolation for vehicles, machine foundations, buildings, and other locations where spring action is required. Additionally, the present disclosure relates to methods for adjusting the spring rate of an air spring assembly.

[0040] In one aspect, a proposed air spring assembly "assembly" and air spring system "system" for a vehicle is disclosed. The assembly and system include a first member, a second member, and a deflectable diaphragm configured to at least partially define a primary air volume and at least partially define a secondary air volume. The deflectable diaphragm is configured to deflect from a first position to a second position due to a change in air pressure differential between the primary air volume and the secondary air volume caused by an amount of one or more loads on the vehicle, correspondingly moving the air spring assembly and system from an extended position to a compressed position, thereby adjusting the spring constant. In one embodiment, a damper unit is configured integrally with the primary air volume and remains partially within the air spring assembly. In another aspect, a damper unit is configured integrally with the primary air volume and remains completely within the air spring assembly.

[0041] In another aspect, an air spring assembly is disclosed that includes a piston spring that is integral with the primary air volume and that together with the piston spring provides stability, load bearing spring action, and shock absorption.

[0042] In yet another aspect, the air spring assembly At least one Spring constant Spring properties including A method of adjusting a pressure in an air spring assembly is disclosed. The method includes providing a spring assembly with a deflectable diaphragm at least partially defining the primary air volume chamber and at least partially defining the secondary air volume chamber, the primary air volume chamber being adjacent to the secondary air volume chamber. The method includes providing an air spring assembly with a deflectable diaphragm at least partially defining the primary air volume chamber and at least partially defining the secondary air volume chamber. At least one Spring constant Spring properties including The method further includes the step of varying the pressure or volume in either or a combination of the primary and secondary air volumes to vary the pressure or volume in the primary and secondary air volumes.

[0043] Although various embodiments of the present disclosure have been described in detail for implementation of the air spring assembly 300 for a vehicle air suspension, those skilled in the art will appreciate that the air spring assembly 300 may likewise be configured for use with machines, buildings, and other structures where spring action is required, and all such embodiments are within the scope of the present disclosure without limitation. Additionally, the number of air spring assemblies 300 implemented in a vehicle, building, machine, or other structure may vary based on the required spring action and load requirements, thereby forming an air spring system.

[0044] Please refer to Figures 1 and 2. Figures 1 and 2 show an exemplary cross-sectional view and a side elevational view, respectively, of a disclosed air spring assembly 300 for a vehicle according to a first embodiment. The air spring assembly 300 includes: 1. At one end is a first member 310, and at the other end is a Second end 351 The air spring assembly 300 further includes a deflectable diaphragm 360 configured to at least partially define a primary air volume 370 and at least partially define a secondary air volume 380 within the air spring assembly 300. The primary air volume 370 and secondary air volume 380 are coaxially configured about an axis (AX). The first member 310 and second member 350 of the air spring assembly 300 are secured to the axle / wheel at one end and to the chassis / subframe of the vehicle at an opposite end by welding, bolting, or other suitable mechanism.

[0045] In one embodiment, air spring assembly 300 includes a flexible wall member 320 that functions like an air bag during operation of air spring assembly 300. Deflectable diaphragm 360 separates a primary air volume chamber 370 and a secondary air volume chamber 380. Primary air volume chamber 370 is defined by inner surface 318 of first member 310, inner surface 354 of second member 350, inner surface 321 of flexible wall member 320, and inner surface 363 of deflectable diaphragm 360, and secondary air volume chamber 380 is defined by inner surface 318 of first member 310 and outer surface 361 of deflectable diaphragm 360.

[0046] In one embodiment, flexible wall member 320 and deflectable diaphragm 360 are hermetically sealed by a number of bands. Deflectable diaphragm 360 is hermetically sealed to first member 310 at first end 311 by band 327 and another band 362, and is hermetically sealed to first member 310 at intermediate end 319 by band 326 and another band 364. Flexible wall member 320 is hermetically sealed to first member 310 by band 328, and is hermetically sealed to second member 350 by band 324.

[0047] Those skilled in the art will appreciate that other suitable attachment methods and other connections may alternatively be used in place of bands to secure the first and second members with the flexible wall member 320 and the deflectable diaphragm 360. Additionally, the primary and secondary air volumes 370, 380 may be constructed or formed in a number of other ways, all of which are within the scope of the present disclosure.

[0048] In one embodiment, the deflectable diaphragm 360 deflects toward the secondary air chamber 380 based on a change in the air pressure differential between the primary air chamber 370 and the secondary air chamber 380 caused by the amount of load placed on the vehicle, forcing the air spring assembly 300 to move between an extended position and a compressed position. When the vehicle is loaded on the air spring assembly 300, the deflectable diaphragm 360 deflects from a first position to a second position. When the load is removed from the air spring assembly 300, the deflectable diaphragm 360 returns to the first position.

[0049] The deflectable diaphragm 360 deflects toward either the primary air volume chamber 370 or the secondary air volume chamber 380, whichever has the relatively lower pressure. The higher the pressure differential between the primary air volume chamber 370 and the secondary air volume chamber 380, the more the deflectable diaphragm 360 can deflect in some embodiments. A higher or substantially higher spring constant is obtained when the pressure in the secondary air volume chamber 380 is higher or substantially higher than the pressure in the primary air volume chamber 370, respectively. Furthermore, a relatively lower or substantially lower spring constant is obtained when the pressure in the secondary air volume chamber 380 is lower or substantially lower than the pressure in the primary air volume chamber 370. Thus, the spring assembly 300 can obtain a desired spring constant by varying the pressure differential between the two chambers 370 and 380.

[0050] In one embodiment, a lower suspension height results in a relatively high spring constant due to a higher pressure in the secondary air volume chamber 380 compared to the primary air volume chamber 370. Thus, a higher pressure differential between chambers 370 and 380 can result in a higher spring constant. Additionally, a lower suspension height results in a relatively low spring constant due to a lower pressure in the secondary air volume chamber 380 compared to the primary air volume chamber 370. Thus, a higher pressure differential between chambers 370 and 380 can result in a lower spring constant.

[0051] Additionally, a higher suspension height results in a relatively higher spring constant due to a higher pressure in the secondary air volume chamber 380 compared to the primary air volume chamber 370. Thus, a higher pressure differential between chambers 370 and 380 can result in a higher spring constant. Additionally, a higher suspension height results in a relatively lower spring constant due to a lower pressure in the secondary air volume chamber 380 compared to the primary air volume chamber 370. Thus, a higher pressure differential between chambers 370 and 380 can result in a lower spring constant.

[0052] In one embodiment, the compression and extension spring constants of the air spring assembly 300 can be made different by varying the pressure in the primary air volume chamber 370 and / or the secondary air volume chamber 380 during the compression and extension cycles, respectively. Different spring constants are achieved by combining different values ​​of pressure in the primary air volume chamber 370 with different values ​​of pressure in the secondary air volume chamber 380. A quantum small change in the pressure differential between the two chambers 370 and 380 results in a rapid change in the spring constant of the air spring assembly 300. Thus, the air spring assembly 300 imparts a quicker response to the active suspension system.

[0053] In one embodiment, the primary air volume chamber 370 and the secondary air volume chamber 380 each include a pair of inlets or passages 312 and 314 for charging air, one inlet 312 for charging air into the primary air volume chamber 370 and a second inlet 314 for charging air into the secondary air volume chamber 380. In one embodiment, a valve assembly consisting of a control valve may be configured with the pair of inlets 312 and 314 to control the supply and release of air from these chambers 370 and 380. Those skilled in the art will appreciate that chambers 370 and 380 may be charged to the same or different air pressures through corresponding inlets 312 and 314 .

[0054] 3, in one embodiment, a proposed air spring assembly 300 is disclosed that includes a damper unit 400 partially within the primary air volume 370 of the air spring assembly 300. The damper unit 400 includes a cylinder 410 and a piston rod 430 that resides partially within the air spring assembly 300 and moves with the air spring assembly 300 from an extended position to a compressed position.

[0055] The damper unit 400 can be attached to a portion of the vehicle, which can be an axle / wheel or chassis, using support 432. The cylinder 410 of the damper unit 400 can be attached to the second member 350 using support 436. The piston rod 430 of the damper unit 400 passes into the air spring through an opening 352 in the second member 350, which is hermetically sealed. The piston rod 430 can be attached to the first member 310 of the air spring at a support 434 at the first end 311.

[0056] 4, in another embodiment, the damper unit 400 may be entirely contained within the primary air volume 370 of the air spring assembly 300. The cylinder 410 of the damper unit 400 may be attached at the first end 311 to the first member 310 using a support 432. The piston rod 430 may be attached to the second member 350 of the air spring using a support 434.

[0057] In one embodiment, the first member 310 and the second member 350 of the air spring assembly 300 are secured to the axle / wheel at one end and to the vehicle chassis / subframe at the opposite end by welding, bolting, or any other suitable mechanism. Additionally, the primary air volume chamber 370 and the secondary air volume chamber 380 may be of any suitable shape, size, and / or configuration. The secondary air volume chamber 380 may be located anywhere relative to the primary air volume chamber 370, such as outside, inside, partially inside, adjacent, or distant from the primary air volume chamber 370. However, a closer location may provide a more rapid response. Those skilled in the art will appreciate that the secondary air volume chamber 380 need not be coaxial with the primary air volume chamber 370.

[0058] Referring to Figure 5, a cross-sectional view of a second embodiment of the proposed air spring assembly having a piston spring is disclosed. The embodiment of spring assembly 300 of Figure 5 is similar to air spring assembly 300, except for a few modifications that are described below. The flexible wall member 320 is not required in the second embodiment air spring assembly 300. The air spring assembly 300 includes a primary air volume 370. Consisting of The piston air spring 500 has one end connected to the wheel. / axle The support 502 can be attached to a portion of the vehicle, which can be a chassis. The cylinder 506 of the piston spring 500 can be At the first end 311 The piston spring 500 may be attached to the first member 310 of the air spring 300 at a support 505. The piston rod 501 of the piston spring 500 may be At the opposite second end 550 The air enters the interior of the air spring 300 through an opening 510 in the second member 503. The piston rod 501 has a piston 508 that moves inside a cylinder 506 along its inner surface 520 and is hermetically sealed to the cylinder 506 by a seal member 507. The cylinder 506 is hermetically sealed to the first member 310 by a seal 514 at the intermediate end 319.

[0059] In one embodiment, the second member 503 has an air vent 504. The second member 503 is fitted to the first member 310 via a band 528. The primary air volume chamber 370 is formed between the piston 508 and the first end 311 of the first member 310 by the inner surface 318 of the first member 310, the inner surface 363 of the deflectable diaphragm 360, and the inner surface 520 of the cylinder 506. The cylinder 506 has at least one passage 509 for allowing air to flow into or out of the cylinder 506 within the primary air volume chamber 370. The piston spring 500 has a stopper 530 suitably fitted to the first member 310 at the first end 311.

[0060] In one embodiment, when a load is applied to a vehicle configured with air spring assembly 300 of FIG. 5, piston rod 501 of piston spring 500 moves from an extended position to a compressed position and deflectable diaphragm 360 deflects from a first position to a second position. Additionally, when the load is removed from the vehicle, piston rod 501 of piston spring 500 Returning to the extended position, the deflectable diaphragm 360 Return to first position.

[0061] In the above-described embodiments of the present disclosure, it can be seen that when the pressure in chamber 370 increases relative to the pressure in chamber 380, deflectable diaphragm 360 deflects toward chamber 380. Similarly, when the pressure in chamber 380 increases relative to the pressure in chamber 370, deflectable diaphragm 360 deflects toward chamber 370.

[0062] Those skilled in the art will appreciate that the air spring assembly 300 carries the full load of the vehicle axle and provides stability to the vehicle. The air spring assembly together with the piston spring 500 provides the spring action to withstand loads and cushion shocks.

[0063] 1-5 may include a number of sensors (not shown) for monitoring and transmitting to the vehicle's electronic controls (not shown) one or more operating parameters of the air spring assembly 300 and the vehicle. The sensors may be arranged to monitor and provide details about the pressures in the primary air volume 370 and the secondary air volume 380. At least one of the following Inside at least One pressure sensor each A selection can be made from pressure sensors that can be attached to the deflectable diaphragm 360. A position sensor (not shown) can be attached to indicate the position of the deflectable diaphragm 360, and a height sensor (not shown) can be attached to indicate the suspension height.

[0064] In one embodiment, a valve assembly consisting of a control valve can be configured with a pair of inlets 312 and 314 to control the supply and release of air from these chambers 370 and 380. Additionally, a valve can be configured with the air vent 504 of the second member 503 in FIG. 5. Additionally, the passage 509 of the cylinder 506 includes a ,one Next air volume chamber 370 Inside or outside of the cylinder 506 A separate valve may be configured to allow and control the airflow.

[0065] In one embodiment, the air spring assembly 300 of FIGS. 1-5 can include a controller operably coupled to the plurality of sensors and the valve assembly. The controller may be an electronic control unit (ECU) of the vehicle, although the controller may be distinct from the ECU as well if the spring assembly is implemented for non-vehicle operation. The controller is configured to receive a plurality of sensor signals from a plurality of vehicle sensors and analyze the received sensor signals to determine desired spring characteristics including at least a spring constant for the vehicle. The controller responsively generates and transmits an output signal to operate the valve assembly to alter the pressure and / or volume in at least one of the primary air volume 370 and the secondary air volume 380 to obtain the desired spring characteristics for the vehicle.

[0066] In one embodiment, the material of the deflectable diaphragm 360 in Figures 1-5 is a stretchable material, such as, but not limited to, a rubber tubing material of a vehicle tire. The deflectable diaphragm can be made of either or a combination of stretchable and non-stretchable materials. Furthermore, the first member 310 is a rigid member and is selected from metal, plastic, or any other suitable material or combination of materials. However, one skilled in the art will appreciate that the first member 310 may be partially or entirely made of flexible / semi-flexible / rigid materials or combinations thereof to perform the same function.

[0067] Referring to FIG. 6, the air spring assembly 300 of FIGS. At least one Spring constant Spring properties including A method 600 for adjusting the spring constant of the air spring assembly is disclosed. The method 600 includes providing 602 a spring assembly 300 with a primary air volume 370 adjacent a secondary air volume 380, with a deflectable diaphragm 360 at least partially defining the primary air volume 370 and at least partially defining a secondary air volume 380. The method 600 includes adjusting the spring constant of the air spring assembly. Spring properties including but not limited toIn order to change the pressure in either or a combination of the primary air volume 370 and the secondary air volume 380, and / or volume The step 604 further includes modifying

[0068] Thus, the present disclosure provides an improved, simplified and cost effective air spring that provides optimal spring rates for a variety of combinations of different loads and suspension heights, thereby providing control, stability, safety and comfort to vehicle occupants. Although several preferred embodiments of the present disclosure have been disclosed, one of ordinary skill in the art would recognize that certain modifications would come within the scope of the present invention.

[0069] Although various embodiments of the present invention have been described above, other and further embodiments of the present invention may be combined without departing from its basic scope. The scope of the present invention is determined by the following claims. The present invention is not limited to the described embodiments, versions or examples, which, when combined with the information and knowledge available to the skilled artisan, are included to enable the skilled artisan to make and use the invention.

Claims

1. An air spring assembly (300) for a vehicle, comprising: a first member (310) at one end and a second member (350) at an opposite end; a deflectable diaphragm (360) configured to at least partially define a primary air volume chamber (370) and to at least partially define a secondary air volume chamber (380), the primary air volume chamber (370) having a first inlet (312) for filling air therein, and the secondary air volume chamber (380) having a second inlet (314) for filling air therein; Equipped with The deflectable diaphragm (360) separates the primary air volume (370) from the secondary air volume (380) such that a change in air pressure differential between the primary air volume (370) and the secondary air volume (380) causes deflection of the deflectable diaphragm (360).

2. 2. The air spring assembly of claim 1, further comprising a damper unit configured such that the primary air volume remains at least partially within the air spring assembly, a first end of the damper unit configured to be coupled to a portion of the vehicle with the first member and a second end of the damper unit configured to be coupled to another portion of the vehicle with the second member, and wherein a piston rod associated with the damper unit is configured to move correspondingly with the air spring assembly from an extended position to a compressed position when the vehicle is loaded.

3. 2. The air spring assembly of claim 1, further comprising a damper unit (400) configured such that the primary air volume (370) remains entirely within the air spring assembly (300), a first end of the damper unit (400) configured to be coupled to a portion of the vehicle with the first member (310) and a second end of the damper unit (400) configured to be coupled to another portion of the vehicle with the second member (350), and a piston rod (430) associated with the damper unit (400) configured to move correspondingly with the air spring assembly (300) from an extended position to a compressed position when the vehicle is loaded.

4. The air spring assembly (300) of claim 1, wherein at least one flexible wall member (320) defines at least a portion of the primary air volume (370).

5. 2. The air spring assembly (300) of claim 1, wherein the primary air volume (370) is defined by an inner surface (318) of the first member (310), an inner surface (354) of the second member (350), an inner surface (321) of a flexible wall member (320), and an inner surface (363) of the deflected diaphragm (360), and the secondary air volume (380) is defined by the inner surface (318) of the first member (310) and an outer surface (361) of the deflected diaphragm (360).

6. 2. The air spring assembly (300) of claim 1, wherein the deflectable diaphragm (360) remains in a first position when air pressures in the primary air volume chamber (370) and the secondary air volume chamber (380) are equal, and wherein the deflectable diaphragm (360) deflects to one or more second positions when there is a change in the air pressure differential between the primary air volume chamber (370) and the secondary air volume chamber (380).

7. 2. The air spring assembly (300) of claim 1, further comprising a plurality of sensors configured with the air spring assembly (300) to monitor one or more operating parameters of the air spring assembly (300) and correspondingly transmit the monitored operating parameters to an electronic control of the vehicle.

8. a piston spring (500) configured to be attached to a portion of the vehicle by a support (502), the piston spring (500) comprising a cylinder (506) and a piston rod (501) configured to be movable with a piston (508) and hermetically sealed with the cylinder (506) by a sealing member (507), the cylinder (506) comprising at least one passage (509) for allowing air flow between the cylinder (506) and the primary air volume (370); 2. The air spring assembly (300) of claim 1, wherein the piston rod (501) moves from an extended position to a compressed position and the biasing diaphragm (360) biases from a first position to a second position due to a change in air pressure differential between the primary air volume (370) and the secondary air volume (380).

9. 1. An air spring system comprising: At least one air spring assembly (300); a plurality of vehicle sensors configured to measure a plurality of vehicle characteristics and responsively generate a plurality of sensor signals; a valve assembly configured to control the supply of air into and out of the at least one air spring assembly (300); a controller operably coupled to the plurality of vehicle sensors and to the valve assembly; The control unit includes: receiving the plurality of sensor signals from the plurality of vehicle sensors; Analyzing the received sensor signals to determine desired spring characteristics including at least one spring constant for the vehicle; an air spring system configured to generate an output signal that actuates the valve assembly to vary pressure in at least one of a primary air volume (370) and a secondary air volume (380) to obtain the desired spring characteristic for the vehicle.

10. A method (600) for adjusting a spring rate of an air spring assembly (300), comprising: providing (602) a primary air volume chamber (370) adjacent a secondary air volume chamber (380) with a deflectable diaphragm (360) at least partially defining the primary air volume chamber (370) and at least partially defining the secondary air volume chamber (380); Varying (604) the pressure or volume within either or a combination of the primary air volume chamber (370) and the secondary air volume chamber (380) to change the spring constant of the air spring assembly (300); A method (600) for adjusting a spring rate of an air spring assembly (300), comprising:

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