Two-portion Suspension Enhancer for Heavy Load Support
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Solution Overview
Problem
Existing vehicular suspension systems, particularly in pick-up trucks, face challenges in maintaining ride comfort and load support when carrying heavy loads, as longer spring-packs compromise load-bearing capacity and increase body roll, while prior suspension enhancers have limited displacement and rapid contact issues leading to discomfort and traction loss during off-road conditions.
Innovation Solution
A vehicular suspension enhancer comprising separate upper and lower spring portions, made from cellular polyurethane foam, which are aligned to engage only when the distance between the axle and frame decreases, providing improved damping and support without limiting maximum wheel travel, and featuring a 'spigot and socket' joint for optimal contact and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If leaf spring-packs are substantially lengthened to improve ride comfort, then ride quality is improved, but load-bearing capacity decreases and body roll increases
Solution Approach 1:
The suspension enhancer is divided into two separate spring portions (first spring portion and second spring portion) that can independently compress and extend. This segmentation allows each spring to be optimized for specific functions: one for ride comfort and the other for load-bearing capacity, resolving the contradiction between improved ride quality and maintained strength under heavy loads.
2Strength
If prior art suspension enhancers are used to support heavy loads, then load support is improved, but wheel travel is limited and ride comfort deteriorates
Solution Approach 1:
The two spring portions are designed with different lengths and stiffness characteristics, allowing the system to dynamically adapt to varying load conditions. When heavily loaded, both springs compress to provide maximum support. When lightly loaded, the system maintains full wheel travel capability, thus resolving the contradiction between load support and wheel travel.
3Strength
If suspension enhancers contact the axle during compression events, then support is provided, but rapid hard contact causes impact events and oscillation
Solution Approach 1:
The first spring portion is positioned to contact the axle before the second spring portion during compression events. This beforehand cushioning arrangement allows the softer first spring to absorb initial impact energy, preventing hard contact and subsequent oscillation, while still providing necessary support during heavy loading conditions.
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 two-portion suspension enhancer enhances ride comfort by maintaining tire contact with the ground, reducing oscillation, and supporting heavy loads effectively, while allowing for increased wheel travel and improved damping characteristics, especially in off-road conditions.
Implementation Method 1
A first spring portion (12) operatively secured to the axle and a second spring portion (14) operatively secured to the frame
Implementation Method 2
The vehicular suspension enhancer is particularly designed for use with vehicles having suspension systems which are designed for ride comfort
Data Source
AI summary
A vehicular suspension enhancer comprises a pair of vertically oriented spring portions, one portion mounted to the axle and the other portion mounted to the frame. Each vehicle axle can be equipped with two suspension enhancers, one enhancer located on each side of an axle. Each of the spring portions are positioned in the space between the axle and the vehicular frame, with the distal ends of each spring portion facing one another with a space between the distal ends defining a gap. The gap between the facing spring portions will increase in response to an increase in the distance between frame and axle.