Coil Spring Rate Adjustment Using Inserts for Bike Suspension
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Solution Overview
Problem
Current coil spring systems in mountain bikes and motorcycles lack an effective adjustment mechanism for optimizing the spring rate, leading to suboptimal ride quality due to fixed spring rates and difficulties in selecting the correct spring rate for individual riders, which can result in bottoming out or inadequate suspension travel.
Innovation Solution
An adjustment system that includes a coil spring with a gap between end and adjacent coils, allowing for incremental adjustment of the spring rate through the use of inserts or a rotatable collar, enabling users to increase the effective spring rate without replacing the spring, thereby optimizing ride quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a coil spring with a fixed spring rate is used, then the suspension can react to very small bumps without stiction, but the spring rate cannot be optimized for individual riders without replacing the spring
Solution Approach 1:
The patent divides the coil spring into segments by introducing spacers that can be inserted between individual coils. This segmentation allows the spring rate to be adjusted in discrete increments by adding or removing spacers, making the adjustment process simple and modular without requiring a complex continuous adjustment mechanism.
Solution Approach 2:
The patent uses spacers as intermediary elements inserted between the coils of the spring. These spacers act as mediators that physically separate the coils and increase the spring rate by reducing the number of active coils. This intermediary approach allows for spring rate adjustment without modifying the spring itself or requiring complex adjustment mechanisms.
2Reliability
If the spring rate is increased to prevent bottoming out, then suspension durability improves, but ride quality deteriorates due to excessive stiffness
Solution Approach 1:
The patent enables dynamic adjustment of the spring rate, allowing riders to change the spring characteristics based on riding conditions. By providing an adjustable system where spacers can be added or removed, the spring rate can be optimized for different scenarios - stiffer for aggressive riding to prevent bottoming out, softer for smooth terrain to maintain ride quality.
Solution Approach 2:
The patent changes the physical parameters of the spring system by introducing spacers that alter the effective number of active coils. This parameter change allows the spring rate to be adjusted without changing the fundamental spring structure, enabling riders to find the optimal balance between durability and ride quality for their specific needs.
3Adaptability or versatility
If multiple springs with different spring rates are provided, then optimal spring rate can be selected for each rider, but cost and device complexity increase
Solution Approach 1:
Instead of providing multiple complete springs, the patent segments the spring adjustment into modular spacers that can be added or removed. This segmentation allows a single spring to be adjusted to multiple different spring rates, providing the versatility of multiple springs without the cost and complexity of actually having multiple complete spring assemblies.
Solution Approach 2:
The patent makes a single spring universal by enabling it to perform multiple functions at different spring rates through the use of adjustable spacers. One spring can serve as a soft spring, medium spring, or stiff spring depending on the spacer configuration, eliminating the need for riders to purchase and manage multiple different spring components.
4Manufacturing precision
If preload adjustment is used to compensate for spring rate mismatches, then sag can be corrected, but the spring rate remains inappropriate for the rider weight and style
Solution Approach 1:
The patent addresses the limitation of preload adjustment by segmenting the spring into adjustable coils using spacers. This allows the actual spring rate to be matched to the rider's weight and style, not just the sag. By physically reducing the number of active coils through spacer insertion, the spring becomes genuinely stiffer rather than just preloaded, providing true spring rate adaptation.
Solution Approach 2:
The patent changes the fundamental parameter of spring rate by altering the effective coil count through spacer insertion. This is different from preload adjustment which only changes the initial compression force. By actually changing the spring rate parameter to match rider specifications, the system provides accurate spring selection without relying on preload compensation.
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
The system allows for precise adjustment of the spring rate, enhancing ride quality by mitigating compression and providing a more linear spring response, allowing riders to fine-tune their suspension settings for specific riding styles and conditions without the need for multiple spring replacements.
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
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AI summary
A system 120 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 30 and 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.