Dual-Rate Spring Coupler With Isolated Crossover Damping
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Solution Overview
Problem
Existing spring crossover systems in vehicle suspension systems often produce noise and harsh jolts during compression events due to the sudden transition between different spring rates.
Innovation Solution
A dual rate spring system with a two-piece spring coupler and a crossover ring, where a crossover isolator or a gas chamber is used to cushion the contact between the spring coupler and the crossover ring, reducing noise and harshness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a dual rate spring system is used to improve suspension performance, then ride quality is improved, but noise and harsh jolts are generated during compression events
Solution Approach 1:
A crossover isolator is introduced as an intermediary component between the spring coupler and the crossover ring. This isolator cushions the contact during compression events, preventing direct metal-to-metal impact while allowing the dual rate spring system to maintain its ride quality benefits. The isolator absorbs the harmful shocks and noise without compromising the suspension performance.
Solution Approach 2:
The crossover isolator is pre-installed in position to cushion potential impacts before they occur. By having the cushioning element already in place between the spring coupler and crossover ring, the system prepares for compression events in advance, preventing noise and harshness before they can be generated during the actual compression event.
2Adaptability or versatility
If a spring coupler and crossover ring system is used to achieve dual rate spring functionality, then suspension adaptability is improved, but sudden transitions between spring rates cause harshness
Solution Approach 1:
The crossover isolator serves as a mediator that softens the transition between different spring rates. While the spring coupler and crossover ring system maintains its adaptability for dual rate functionality, the isolator intervenes during the transition phase to prevent abrupt changes, thereby improving the stability and smoothness of the rate transition.
Solution Approach 2:
The introduction of the crossover isolator changes the physical parameters of the transition process. By adding this compliant element, the system modifies the stiffness and damping characteristics during the transition phase, transforming the sudden, harsh rate change into a more gradual and stable transition while preserving the adaptive dual rate capability.
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 rate spring system effectively reduces noise and harshness by smoothing the transition between spring rates during compression events, enhancing ride quality and reducing potential damage to vehicle components.
Implementation Method 1
a gas chamber is used to cushion the contact between the spring coupler and the crossover ring
Implementation Method 2
a crossover isolator or a gas chamber is used to cushion the contact between the spring coupler and the crossover ring
Data Source
AI summary
A dual rate spring system is disclosed. The dual rate spring system can include a first spring and a spring coupler that have different spring rates. The dual rate spring system can include a two piece crossover ring, a two piece spring coupler, or both. The two piece crossover ring can include a first damper. The two piece spring coupler can include a second damper. The first and second damper can reduce a noise or harshness of jolt associated with a transition from the first spring to the second spring.