Composite Leaf Spring Variable Rate Suspension

The patent combines the variable spring rate functionality into a single leaf spring by integrating bumpers directly onto the spring body, merging what would traditionally be separate spring components into one unified structure. This eliminates the need for additional parallel spring arrangements while achieving variable spring rate characteristics through the bumper contact mechanism that engages at different deflection points.

The leaf spring incorporates bumpers that dynamically engage and disengage based on the spring's deflection state. At small deflections, the bumpers are spaced apart providing a first spring rate, while at large deflections, the bumpers contact the chassis rail providing a second spring rate. This dynamic engagement mechanism allows the single spring to adapt its characteristics without requiring additional static spring components.

The invention merges the variable spring rate adjustment capability into the basic leaf spring structure by attaching bumpers directly to it. Instead of adding separate spring arrangements, the bumpers are integrated onto the spring body itself, creating a unified component that provides both structural support and variable rate functionality, thereby reducing overall device complexity.

The leaf spring with integrated bumpers serves multiple functions: it provides the primary suspension function, achieves variable spring rate characteristics, and eliminates the need for separate adjustment mechanisms. The single component performs what would traditionally require multiple dedicated parts, simplifying the overall system architecture.