Dual Flex Spring Assembly for Extended Off-Road Suspension Droop
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Solution Overview
Problem
Offroad vehicles face challenges in handling extreme obstacles without the need for vehicle lifting, which introduces additional issues.
Innovation Solution
A dual flex spring assembly comprising a top retaining plate, a bottom retaining plate, a bolt, a nut, and an open-coiled helical spring, allowing for extended suspension droop without altering the vehicle's standard coil spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the vehicle is lifted to allow for more suspension, then the suspension capability is improved, but the vehicle stability and center of gravity are worsened
Solution Approach 1:
The patent implements nesting by placing the open-coiled helical spring inside the middle opening of the outer coil spring. This nested configuration allows both springs to work together in a compact arrangement, providing extended suspension droop (improving adaptability) without requiring vehicle lifting (maintaining stability). The inner spring engages first during compression, followed by the outer spring, creating a progressive suspension system.
Solution Approach 2:
The patent utilizes the vertical dimension by arranging the springs in a nested configuration along the suspension droop direction. The inner open-coiled helical spring and outer coil spring are positioned concentrically, with the inner spring having a smaller diameter to fit within the outer spring's middle opening. This dimensional arrangement maximizes suspension travel in the vertical direction without increasing horizontal footprint or requiring vehicle modification.
2Length of moving object
If a dual flex spring assembly is added to enhance suspension droop, then the suspension travel is improved, but the device complexity is worsened
Solution Approach 1:
The patent reduces complexity by nesting the inner open-coiled helical spring within the outer coil spring's middle opening. This configuration allows two spring systems to function together while occupying the same space, effectively increasing suspension droop without adding separate mounting locations or complex linkage mechanisms. The shared mounting structure (top and bottom retaining plates with common bolt/nut assembly) further simplifies the overall assembly.
Solution Approach 2:
The patent achieves multi-functionality by designing the spring assembly to serve multiple purposes: the inner open-coiled helical spring provides initial suspension compliance, while the outer coil spring provides additional droop travel. Both springs share the same mounting structure and work together to handle varying load conditions, eliminating the need for separate suspension systems for different operating conditions and reducing overall device complexity.
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 dual flex spring assembly enhances suspension droop by up to 10-20% or 6-12 inches, maintaining vehicle levelness over uneven terrain.
Implementation Method 1
an open-coiled helical spring disposed between the top retaining plate and the bottom retaining plate
Implementation Method 2
a coil spring disposed on the bottom retaining plate such that the open-coiled helical spring is arranged within a middle opening of the coil spring
Data Source
AI summary
A dual flex spring assembly for an offroad vehicle (or any vehicle) is disclosed. The dual flex spring assembly may extend the suspension droop beyond the standard droop of a wheel of the vehicle while using a standard coil spring. For example, a dual flex spring assembly may include a top retaining plate having a hole, a bottom retaining plate, a bolt extending from the bottom retaining plate through the hole in the top retaining plate; a nut coupled with an end of the bolt adjacent to the top retaining plate; and an open-coiled helical spring disposed between the top retaining plate and the bottom retaining plate such that the bolt extends through a middle opening of the open-coiled helical spring.