Integrated and self-contained suspension assembly having an on-the-fly adjustable air spring

• US 10,202,166 B2
• Filed: 12/30/2016
• Issued: 02/12/2019
• Est. Priority Date: 06/25/2002
• Status: Expired due to Term

• Current Assignee: Fox Factory Incorporated
• Original Assignee: Fox Factory Incorporated
• Inventors: Fox, Robert C.
• Primary Examiner(s): Nguyen, Xuan Lan
• Application Number:
  US15/395,594
• Publication Number:
  US 20170106937A1
• Time in Patent Office: 774 Days
• Field of Search: 188278, 18832213, 18832214, 1883222, 1882991, 267 6426, 267 6411, 267 6428
• CPC Class Codes: B60G 15/12 and fluid damper
• CPC Class Codes: B60G 17/0523 Regulating distributors or valves for pneumatic springs
• CPC Class Codes: B60G 2300/12 Cycles; Motorcycles
• CPC Class Codes: B60G 2500/20 Spring action or springs
• CPC Class Codes: B62K 2025/048 with suspension manual adjustment details
• CPC Class Codes: B62K 2201/08 Fluid springs
• CPC Class Codes: B62K 25/04 for mounting axles resiliently on cycle frame or fork for sidecars, forecars or the like B62K27/06
• CPC Class Codes: F16F 13/002 comprising at least one fluid spring F16F13/005, F16F13/02, F16F13/04 take precedence
• CPC Class Codes: F16F 2228/066 Variable stiffness
• CPC Class Codes: F16F 9/0209 Telescopic F16F9/04 takes precedence
• CPC Class Codes: F16F 9/0236 characterised by having a hollow piston rod
• CPC Class Codes: F16F 9/06 using both gas and liquid F16F9/486 take precedence; self-pumping fluid springs B60G17/044
• CPC Class Codes: F16F 9/3257 in twin-tube type devices
• CPC Class Codes: F16F 9/46 allowing control from a distance , i.e. location of means for control input being remote from site of valves, e.g. on damper external wall attachment of valve units to cylinders F16F9/325
• CPC Class Codes: F16F 9/461 characterised by actuation means

Abstract

An integrated and self-contained suspension assembly having a gas spring integrated with a shock absorber (damper) is described. The rigid gas cylinder of the air spring is divided into a first gas chamber and a second gas chamber. A flow port connects the first and second gas chambers, and can be manually opened or closed by valve and a simple one-quarter turn rotation of an external knob to instantly switch the gas spring between two different spring rates. The different spring rates are functions of the separate or combined volumes of the two. gas chambers. The integrated suspension assembly is compactly packaged and self-contained, i.e., does not require any externalities, such as gas sources or electricity, to operate.

Claims

1. A suspension unit operable between a compressed position and an extended position, said suspension unit comprising:

a first gas chamber;

a second gas chamber, said second gas chamber biasing said suspension unit toward said extended position; and

a valve assembly comprising;

a valve member having;

an open position where said valve assembly provides open fluid communication between said first gas chamber and said second gas chamber such that a volume of said first gas chamber and a volume of said second gas chamber are effectively combined during compression of said suspension unit; and

a closed position where said valve assembly prevents gas flow from said second chamber to said first chamber;

a user-operable travel adjust lever coupled to said valve assembly, said user-operable travel adjust lever configured to enable a user to place said valve member in said open position or said closed position;

a compression chamber at least substantially filled with damping fluid;

a rebound chamber at least substantially filled with said damping fluid; and

a damping piston operable to dampen flow of said damping fluid between said compression chamber and said rebound chamber in response to movement of said suspension unit.

2. A suspension unit operable between a compressed position and an extended position, said suspension unit comprising:

a first gas chamber;

a second gas chamber, said second gas chamber biasing said suspension unit toward said extended position; and

a valve assembly comprising;

a valve member having;

an open position where said valve assembly provides open fluid communication between said first gas chamber and said second gas chamber such that a volume of said first gas chamber and a volume of said second gas chamber are effectively combined during compression of said suspension unit; and

a closed position where said valve assembly prevents gas flow from said second chamber to said first chamber;

a travel adjust lever coupled to said valve assembly, said travel adjust lever configured to enable a user to place said valve member in said open position or said closed position;

a compression chamber at least substantially filled with damping fluid;

a rebound chamber at least substantially filled with said damping fluid; and

a damping piston operable to dampen flow of said damping fluid between said compression chamber and said rebound chamber in response to movement of said suspension unit.

3. The suspension unit of claim 2 wherein said travel adjust lever rotates 90 degrees between a first travel adjust lever position in which said valve member in said open position and a second travel adjust lever position in which said valve member in said closed position.