Adjustable Coil Spring Rate via Gap Insertion
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Solution Overview
Problem
Current coil spring systems in mountain bikes and motorcycles lack an efficient and cost-effective method for adjusting the spring rate, leading to suboptimal ride quality due to fixed spring rates that do not account for individual rider preferences and varying terrain conditions, often resulting in either suspension bottoming out or reduced travel.
Innovation Solution
An adjustment system that includes a coil spring with a gap between end coils, allowing for the insertion of interchangeable wedge inserts or a rotatable collar to adjust the effective spring rate without altering the spring's length, enabling incremental changes to the spring rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a coil spring with a fixed spring rate is used, then the suspension can react to small bumps without stiction, but the spring rate cannot be adjusted to match individual rider preferences and terrain conditions
Solution Approach 1:
The coil spring is segmented by introducing a gap between coils, creating distinct sections. This segmentation allows selective compression of spring sections, enabling variable spring rate adjustment while maintaining the overall spring structure, thus resolving the contradiction between adaptability and device complexity
Solution Approach 2:
The suspension system transitions from a static fixed spring rate to a dynamic adjustable spring rate through the gap mechanism. The gap allows the spring to transition between different compression states, providing dynamic adaptability to various riding conditions without requiring multiple springs or complex replacement systems
2Adaptability or versatility
If multiple coil springs with different spring rates are provided, then riders can optimize for different terrains and weights, but the cost and complexity of maintenance increase
Solution Approach 1:
A single coil spring design incorporates multi-functionality through the gap mechanism, allowing it to serve multiple spring rate purposes. The same spring can operate in different compression modes to provide various effective spring rates, eliminating the need to manufacture, store, and maintain multiple different spring variants
Solution Approach 2:
The spring's effective parameters are changed by utilizing the gap mechanism to alter compression characteristics. By controlling which sections of the spring compress (before or after gap closure), the system changes the effective spring rate parameter without physically changing the spring itself, reducing manufacturing and maintenance costs
3Manufacturing precision
If preload adjustment is used to compensate for soft springs, then sag can be corrected, but the spring rate remains unchanged and travel is reduced
Solution Approach 1:
The spring is divided into sections by the gap, allowing independent control of compression stages. This segmentation enables proper sag adjustment through controlled compression of specific sections while preserving full travel range, unlike uniform preload that reduces overall travel
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system allows for precise adjustment of the spring rate, enhancing ride quality by accommodating individual preferences and terrain demands, reducing the need for multiple springs and addressing manufacturing tolerances, while being cost-effective and easy to implement.
Implementation Method 1
The insert occupies a portion of the gap and contacts the end coil and the adjacent coil to mitigate compression of the adjacent coil toward the end coil when the second engagement element is engaged with the first engagement element
Data Source
AI summary
A system for easily adjusting spring rate of a rear shock for mountain bikes or motorcycles without changing an actual overall spring length. The system may include a coil spring a body sized and structured to engage with the coil spring. The spring rate may be adjusted by selectively placing the body between adjacent coils of the spring to deactivate up to one spring coil adjacent the end of the spring.