Leaf Spring Reinforcing Spring U-Bolt Nesting
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Solution Overview
Problem
Current leaf spring systems fail to provide a balance between a comfortable ride and adequate load-carrying capacity, leading to spring sag and safety issues, especially when vehicles are loaded or towing trailers, due to inadequate tensioning and design limitations that result in u-bolt snapping, chassis damage, and reduced traction and braking performance.
Innovation Solution
A leaf spring system incorporating a reinforcing spring with adjustable attachment mechanisms that allow for pivotal and sliding movements, reducing rebound forces and distributing load more effectively, thereby enhancing the resilience and support of the leaf spring assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standard leaf spring assembly is used to provide a comfortable ride, then ride comfort is improved, but load-carrying capacity deteriorates and spring sag occurs under heavy loads
Solution Approach 1:
The reinforcing spring is nested within the U-bolt assembly, with the U-bolt forming a loop that encompasses the reinforcing spring. This nested configuration allows the reinforcing spring to be integrated into the existing suspension structure without adding significant external bulk, while still providing enhanced load-carrying capacity and preventing spring sag under heavy loads while maintaining ride comfort
2Strength
If u-bolts are used to tension the leaf spring assembly to improve load carrying, then load support is improved, but the u-bolts are prone to snapping and breaking under continuous weight and movement
Solution Approach 1:
The reinforcing spring introduces dynamic flexibility to the U-bolt assembly, allowing it to accommodate continuous weight and movement without rigid constraint. This dynamic capability prevents the U-bolt from snapping and breaking under varying loads, while still providing the necessary load support through the elastic deformation of the reinforcing spring
3Strength
If a bulky plate is added to the leaf spring system to enhance support, then load carrying is improved, but it interferes with LPG and petrol tanks and exhaust systems
Solution Approach 1:
The reinforcing spring is nested within the U-bolt assembly, utilizing the existing space around the leaf spring without requiring additional external space. This nested configuration provides enhanced load carrying capacity while avoiding interference with LPG and petrol tanks and exhaust systems that would be caused by bulky external plates
4Ease of operation
If the vehicle suspension is softened to improve comfort, then ride comfort is improved, but steering and braking performance deteriorate and safety is compromised
Solution Approach 1:
The reinforcing spring is pre-formed with a curved configuration that provides progressive resistance to suspension travel. This curved geometry allows the spring to maintain a soft ride quality for normal driving conditions while progressively increasing support under heavy loads to maintain steering and braking performance and overall vehicle safety
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 solution significantly reduces sag, improves load-carrying capacity, enhances stability and braking performance, and extends the lifespan of the leaf spring assembly by distributing load more evenly and preventing damage from over-tightening, while maintaining a comfortable ride even under heavy loads.
Implementation Method 1
The reinforcing spring has at least one section, which provides resilience to the leaf spring system
Implementation Method 2
the at least one attachment mechanism has a sliding means which allows at least one leaf of the leaf spring assembly to stretch relative to the connecting member while supporting the leaf spring assembly
Data Source
AI summary
The invention provides a leaf spring system which supports a leaf spring assembly using attachment mechanisms which allows normal operation of the leaf spring assembly while providing support through a resilient deformable reinforcing spring.