Offset Washer Protrusion for Camber Adjustment
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Solution Overview
Problem
Vehicles with non-adjustable camber angles face challenges in adjusting camber due to limited flexibility in offset washers, which restricts camber change and clamp load, increasing manufacturing costs and installation complexity.
Innovation Solution
An offset washer with a protrusion having a longitudinal width different from the body thickness, configured to be inserted into a receiving aperture on a vehicle suspension system, and an adjustment bolt with three separate centerlines to provide increased camber adjustment range and clamp load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional offset washer with a tang formed from the same material thickness as the washer body is used, then the washer can be manufactured simply, but the ability to space the washer within the receiving slot is limited to the thickness of the washer, restricting camber adjustment range and clamp load
Solution Approach 1:
The patent introduces a protrusion that extends from the rear surface of the washer body, adding a dimensional element perpendicular to the washer's main plane. This protrusion can extend beyond the front surface of the washer, creating a multi-level structure that enables greater spacing flexibility within the receiving slot without increasing the washer's overall thickness. This dimensional addition directly resolves the contradiction by providing adjustable camber range while maintaining structural simplicity.
Solution Approach 2:
The washer is segmented into distinct functional zones: the main washer body for clamping, the protrusion for spacing adjustment, and the tang for insertion. This segmentation allows each element to perform its specific function optimally - the protrusion provides camber adjustment range while the main body maintains clamp load, resolving the contradiction between adjustability and structural simplicity.
2Adaptability or versatility
If the washer thickness is increased to provide greater spacing flexibility, then camber adjustment range improves, but manufacturing complexity and costs increase
Solution Approach 1:
Instead of increasing the washer's overall thickness, the patent utilizes the protrusion extending from the rear surface to create additional spacing capability. This approach provides greater spacing flexibility (improving adaptability) without requiring a thicker washer body, thereby maintaining manufacturing simplicity and controlling costs.
Solution Approach 2:
The patent changes the geometric parameters of the washer by adding a protrusion with specific dimensional relationships - the protrusion height, its extension beyond the front surface, and its positioning relative to the aperture. These parameter changes enable spacing flexibility without requiring overall thickness increase, resolving the contradiction between adaptability and ease of manufacture.
3Adaptability or versatility
If multiple washers are used to achieve greater camber adjustment, then adjustment range improves, but device complexity and installation difficulty increase
Solution Approach 1:
The patent combines multiple functional elements (spacing capability, clamping surface, and insertion feature) into a single integrated washer component. The protrusion provides spacing equivalent to what would otherwise require multiple separate washers, while the single-bolt installation process remains simple. This merging resolves the contradiction by providing cumulative adjustment range without increasing installation complexity.
Solution Approach 2:
The single washer design serves multiple functions: the main body provides clamping, the protrusion provides spacing and camber adjustment, and the tang provides insertion capability. This multi-functionality replaces what would otherwise require multiple specialized components, improving adaptability while maintaining ease of operation during installation.
Data Source
AI summary
An offset washer for adjusting the camber angle in a vehicle is disclosed. The offset washer includes a body having an upper surface and a lower surface, an aperture extending through the body, and a protrusion having a longitudinal width different than the body thickness. The protrusion is configured to be inserted into a receiving aperture on a flange of a vehicle suspension system. The protrusion is defined by a formed upset defining a step in the material along a portion of the edge of the aperture, which is formed by upsetting the portion of the edge of the aperture when forming the aperture.