IN THE PATENT COOPERATION TREATY

ADJUSTABLE AIR SPRING/COIL SPRING COMBINATION SUSPENSION SYSTEM

INVENTORS: V. JEFFREY MULLICAN and VERNON T. MULLICAN

ASSIGNEE: TLC SUSPENSIONS, LLC

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of US provisional Application No. 60/928,885, filed 11 ^th May 2007, and titled "Adjustable Air Spring/Coil Spring Combination Suspension System"; inventors: V. Jeffrey Mullican and Vernon T. Mullican, the entire disclosure of which is hereby incorporated by reference for all purposes.

Other applications related by inventorship and subject matter include the following: US Patent application No. 1 1/281,606 "Novel Air Spring/Coil Spring Suspension System" filed 18 ^th November 2005 that claims the benefit to Provisional Application No. 60/629,682 filed Nov. 18 ^th 2004; US application No. 11/349,262 filed 8 ^th February 2006, titled "Air Spring/Coil Spring Suspension System" that claims the benefit of the priority of Provisional Application No. 60/651,177 filed Feb. 8 ^th 2005, and Provisional Application No. 60/696,581 filed JuI. 1 ^st 2005, filed November 18 ^th 2005; the entire disclosures of all these applications and patents is hereby incorporated by reference for all purposes.

FIELD OF THE INVENTION

This invention relates to suspension systems for vehicles.

BACKGROUND

In a previous Provisional Patent Application filed by co-inventor herein V. Jeffrey Mullican on November 18, 2004, titled AIR SPRING/COIL SPRING COMBINATION SUSPENSION SYSTEM, USSN 60/629,682, a new suspensions system was disclosed which employs a novel combination of pairs of springs including an air spring and a coil spring arranged around a common central axis and placed within retaining housings that in turn rest on platforms mounted to the rear axle. A non-provisional patent application was subsequently

filed on November 18, 2005 and assigned USSN 11/281,606, hereby incorporated by reference for all purposes.

In a later Provisional Patent Application filed by co-inventors V. Jeffrey Mulllican and Raymond C. Rawn on February 8, 2005 titled IMPROVED AIR SPRING/COIL SPRING COMBINATION SUSPENSION SYSTEM, and assigned USSN 60/651,177, hereby incorporated by reference for all purposes, a novel lower support platform and inclination plates were disclosed that attach to existing leaf spring assemblies and do not put stress on the rear axles. Also frame brackets were disclosed that attach the upper support bracket to the frame of the vehicle. A non-provisional patent application was subsequently filed on February 8, 2006 and assigned USSN 11/349,262, hereby incorporated by reference for all purposes.

The previous lower support platform design required dismantling the truck's suspension system by removing factory U-bolts and shackles and reinstalling them with the lower support bracket and inclination plates. This presented a risk of harm to the person installing the unit, risk of damage to the vehicle and required additional time for installation. Further, the device required different versions to be installed between different classes of vehicles such as common pick-up trucks and vans. For example, a version for 1/2 -ton trucks would not fit a 3/4-ton truck or a 1 -ton truck. The previous invention as disclosed does not fit vehicles with axles on top of the leaf springs typically found on less than 1 /2-ton American- made pick-up trucks. The previous frame bracket design interfered with existing brake lines in certain vehicles including Dodge RAM 1500 pick-up trucks. The invention previously disclosed improved the ride characteristics of many vehicles but did not improve the ride characteristics (in particular, smoothness) of certain other vehicles including but not limited to Dodge Ram 1500 pick-up trucks.

The purpose of this invention is to provide a novel design that does not require unbolting the factory shackles and U-bolts of existing rear leaf spring suspensions to install the device. Further, the invention provides a novel adjustable design allowing a single device to be installed on different size trucks and vans. For example it can be installed on 1/2 ton, 3/4 and 1 ton pick-up trucks and vans and can be adjusted for various vehicle frame widths. This design is easier-to-install and more adaptable for use on trailers. This design also eliminates inclination plates and interference with brake lines on certain vehicles, for example, Dodge RAM 1500. The invention also includes height adapters that are used to improve the ride in certain vehicles.

OBJECT(S) OF THE INVENTION

Accordingly, it is an object of the present improvement invention to provide a combination suspension system without inclination plates that can be installed on vehicles that have leaf springs above or below the rear axle.

It is a further object of the improvement invention to provide improved upper and lower frame brackets adjustable for various pick-up trucks and other vehicles wherein the improvement invention does not interfere with brake lines on certain vehicles.

It is a further object of the improvement invention to provide an adjustable lower support assembly consisting of a lower support member and "L" shaped adjustable beams so the improvement invention is useful on a variety of vehicles including 1/2 ton, 3/4 ton and 1 ton pick-up trucks and vans typically made in America during the last 20 years. The invention can be used for trailers that employ leaf springs such as horse trailers, car trailers and recreational trailers.

It is a further object of the improvement invention to provide an embodiment that can be sized for a particular vehicle and installed on top of the leaf springs without dismantling the existing rear suspension.

It is a further object of the improvement invention to provide coil spring height adapters to improve ride characteristics on certain vehicles.

It is a further object of the improvement invention to provide a suspension that improves the ride, steering, handling and braking characteristics, in addition to the load- carrying capabilities, of vehicles with leaf spring suspensions including pick-up trucks, vans and trailers or any vehicle with a leaf spring suspension.

SUMMARY OF THE INVENTION

The present invention adds a supplemental suspension system to vehicles. As disclosed in provisional and regular applications and mentioned above, the suspension function is provided by a pair of Spring Assembly 39 which are comprised of Air Springs 30 each of which is fixedly mounted to one of a pair of Coil Springs 38 by use of Coil Spring Retainer 35. The upper ends of each Spring Assembly 39 are rigidly attached to Upper Support Assembly 22 that is itself attached to frame F of the vehicle with Lower Frame Bracket 64 and Upper Frame Bracket 66 and rests underneath truck bed B. The lower end of each Spring Assembly 39 is contained within Coil Spring Housings 40a that are part of Lower

Support Member 51. The lower end of each Spring Assembly 39 may or may not be fixedly attached to Lower Support Member 51. Adjustable Lower Support Assembly 48 is mounted on top of and attached to existing leaf springs LS of the vehicle by use of Added U-Bolts 114.

When Air Springs 30 are inflated, Air Springs 30 and Coil Springs 38 work together to add additional lift, and improve ride and driving control. When a heavy weight is present, adding additional air to Air Springs 30 expands Air Springs 30 and Coil Springs 38 fully compress into Coil Spring Housings 40a and Air Springs 30 alone operate.

Upper Support Assembly 22 consists of Upper Support Member 21 and a pair of Upper Frame Brackets 66, each of which are attached to opposite ends of Upper Support Member 21 and a pair of Lower Frame Brackets 64, each of which are attached to one each of Upper Frame Brackets 66. Upper Support Assembly 22 is attached to frame F by bolts B inserted through holes in Lower Frame Brackets 64 into mounting holes that exist in frame F on many vehicles including American-made full-size pick-up trucks (or holes could be drilled if needed). The invention includes Lower Frame Brackets 64 and Upper Frame Brackets 66 that are shown in the Figures.

Lower Support Member 51 is made up of Lower Support Plate 50, Strongbacks 52 (52a is the Front Strongback and 52b is the Rear Strongback) and Coil Spring Housings 40a all fixedly mounted together as shown in the Figures.

Adjustable Lower Support Assembly 48 is made up of Lower Support Member 51, two Rear Adjustment Beams 102 and two Front Adjustment Beams 104 that adjustably mount on each end of Lower Support Member 51 through holes or slots in Strongbacks 52a and 52b and slots in Rear Adjustment Beams 102 and Front Adjustment Beams 104. Note that throughout this specification, where adjustment is provided by slots (overlapping between two metal plates, for example, so as to provide a space for a screw or bolt to be positioned securing the two plates), overlapping holes or combinations of holes and slots of any dimension may equally be provided.

When mounted on a vehicle, each of Front and Rear Adjustment Beams 104 and 102 rest on top of leaf springs LS and are fixedly mounted thereto by use of Added U-Bolts 114 as shown in Figures 2, 3 and 4. Each of Front Adjustment Beams 104 mount toward the front of the vehicle and each of Rear Adjustment Beams 102 mount toward the rear of the vehicle.

Spring Assembly 39 consists of Air Spring 30, Single Attachment Plate 33, Coil Spring Retainer 35 and Coil Spring 38. Coil Spring Retainer 35 is positioned at one end of Coil Spring 38 and fixedly mounts Coil Spring 38, Single Attachment Plate 33 and Air Spring

30 together to form Spring Assembly 39 with the use of bolts B as generally shown in Figure 5. Bolts B go through Coil Spring Retainer 35 and Single Attachment Plate 33 into threaded holes in Air Spring 30 thereby attaching Spring Assembly 39 together. The tops of two Spring Assembly 39 fixedly mount to Upper Support Member 21. The lower portion of Coil Springs 38 can be positioned so that it floats vertically within Coil Spring Housing 40a as shown in Figures 1, 6 and 12. Alternatively the lower portion of Coil Springs 38 can be fixedly attached to Lower Support Member 51 by ordinary means.

Additional and alternative elements will be discussed below.

The improvement comprises a new design for Upper Frame Bracket 66 and Lower Frame Bracket 64 that does not interfere with brake lines found on some existing vehicles.

The improvement comprises 1/2-Circle Height Adapters 110 useful on certain vehicles including, but not limited to, the Dodge Ram 1500 to improve ride characteristics.

The improvement comprises Front Adjustment Beams 104 and Rear Adjustment Beams 102 that are fixedly mounted to Lower Support Member 51 and rest on top of and attach to leaf springs LS by the use of Added U-Bolts 114. Front Adjustment Beams 104 and Rear Adjustment Beams 102 keep Lower Support Member 51 horizontal and are adjustable so the improvement invention fits on various sized vehicles.

The improvement comprises Front Adjustment Beam Extenders 108 and Rear Adjustment Beam Extenders 106 useful on vehicles that have the leaf springs mounted below the axle such as, including but not limited to, less-than-l/2-ton American pick-up trucks such as Ford Ranger, Chevrolet S-10 and Dodge Durango.

When leaf springs LS are mounted below axle A there is a greater distance between leaf springs LS and Adjustable Lower Support Assembly 48. Also, the object of the invention is to avoid placing stress on Axle A. Use of the Front and Rear Adjustment Beam Extenders 108 and 106 permit Adjustable Lower Support Assembly 48 to be fixedly attached to leaf springs LS so positioned.

BRIEF DESCRIPTION OF THE FIGURES

Fig. 1 is a schematic diagram showing a perspective front view of the standard elements of the invention fully assembled but not installed on a vehicle.

Fig. 2 is a schematic diagram showing the right-hand portion of the preferred embodiment from a rear 45 -degree angle installed on a vehicle.

Figure 3 is a schematic diagram of Adjustable Lower Support Assembly 48 with Front Adjustment Beam Extenders 108 and Rear Adjustment Beam Extenders 106 installed on the Front and Rear Adjustment Beams 104 and 102 respectively.

Figure 4 is a side view drawing of the preferred embodiment for vehicles with leaf springs LS under axle A showing Front Adjustment Beam Extenders 108 and Rear Adjustment Beam Extenders 106. The front side is to the left of the figure and the rear side is to the right of the figure.

Figure 5 is a side exploded view of the preferred embodiment for vehicles with leaf springs LS under axle A showing Front Adjustment Beam Extenders 108 and Rear Adjustment Beam Extenders 106. The front side is to the left of the figure and the rear side is to the right of the figure.

Figure 6 is a drawing of the left rear view of the invention for vehicles with the leaf springs LS under axle A.

Figure 7 is a drawing of the top view of 1/2-Circle Height Adapters 110.

Figure 8 is a drawing of one side of the major components of the invention with 1/2- Circle Height Adapters 110 positioned to be installed.

Figure 9 is a drawing of one side of the major components of the invention with 1/2- Circle Height Adapters 1 10 installed.

Figure 10 is a drawing of a bottom view of one end of the Fixed Lower Support Assembly 48' according to the invention.

Figure 11 is a drawing of a side view of the left side of Fixed Lower Support Assembly 48' according to the invention.

Figure 12 is a drawing of a rear view of the left side of the invention with Fixed Rear Strongbacks with Flange 52b'.

Figure 13 is a drawing of the major component parts of the improvement invention.

REFERENCE NUMERALS IN DRAWINGS

1 Upper Support Member 54 Rear Strongback Flange

Upper Support Assembly 56 Nut 8 Bolt 64 Lower Frame Bracket 0 Air Spring 66 Upper Frame Bracket

Single Attachment Plate 68 Inclination Plate

Coil Spring Retainer Assembly 102 Rear Adjustment Beam A Upper Coil Spring Retainer 104 Front Adjustment Beam B Lower Coil Spring Retainer 106 Rear Adjustment Beam

Single Coil Spring Retainer Extender

Coil Spring 108 Front Adjustment Beam Extender

Spring Assembly 110 1/2-Circle Height Adapter a Coil Spring Housing 112 1/2-Circle Hose Clamp Band

Adjustable Lower Support Assembly 114 Added U-BoIt ' Fixed Lower Support Assembly A Axle

Lower Support Plate B Bed of pick-up truck 1 Lower Support Member Bolt Bolt

Strongbacks D Differential a Front Strongback F Frame a' Front Fixed Strongback with Flange LS Leaf Spring b Rear Strongback S Shackle b' Rear Fixed Strongback with Flange U U-bolt

Front Strongback Flange

DESCRIPTION OF THE EMBODIMENTS

One of the improvements in the present invention is the Adjustable Lower Support Assembly 48. The central components of Adjustable Lower Support Assembly 48 are Lower Support Member 51, Front Adjustment Beams 104 and Rear Adjustment Beams 102. Lower Support Member 51 is an elongated rectangular member which spans most of the width of the frame of a vehicle and is narrower than disclosed in previous applications. This is because the narrower width is compensated for by the addition of

the Front and Rear Adjustment Beams 104 and 102. It is arched in the middle to clear the rear differential housing in certain vehicles. Lower Support Member 51 is formed by fixedly attaching Front and Rear Strongbacks 52a and 52b perpendicularly to Lower Support Plate 50. The Front and Rear Strongbacks 52a and 52b are attached to Lower Support Plate 50 partway up the sides of Front and Rear Strongbacks 52a and 52b so that Lower Support Member 51 has a general I-beam configuration.

In the preferred embodiment of Lower Support Plate 50, Front Strongback 52a and Rear Strongback 52b are made of metal such as 1/4" steel plate. The preferred embodiment of Lower Support Plate is shown in Figures.

Strongback 52, the preferred embodiment of front strongback 52a, and the preferred embodiment of Rear Strongback 52b is shown in the various Figures.

Attached to Lower Support Member 51 is a pair of Front and Rear Adjustment Beams 104 and 102 each made of 1/4" steel. Front and Rear Adjustment Beams 104 and 102 are generally L-shaped with a vertical portion and a horizontal portion. There are elongated attachment slots formed in the vertical and horizontal portions of each of the Front and Rear Adjustment Beams 104 and 102. These slots allow the Front and Rear Adjustment Beams 104 and 102 to be adjustably positioned along each of the ends of Lower Support Member 51. Thus the overall width of the device is adjustable by the placement and alignment of Lower Support Member 51 and a pair of Front and Rear Adjustment Beams 104 and 102 attached to each end of Lower Support Member 51 in order to accommodate different dimensions between leaf springs LS on different vehicles.

Each end of Adjustable Lower Support Assembly 48 is positioned on top of one of leaf springs LS and held in place by the use of Added U-bolts 114 through slots in the generally horizontal portion of Rear Adjustment Beam 102 (84°) and slots in the generally horizontal portion of Front Adjustment Beam 104 (96°). The device is adjustable to fit many different vehicles, including but not limited to 1/2 -ton, 3/4-ton and 1-ton pick-up trucks.

The preferred embodiment of Front Adjustment Beam 104 is constructed with a 96° angle between the vertical and horizontal portions as shown in the Figures. Rear Adjustment Beam 102 is constructed with an 84° angle between the vertical and

horizontal portions as shown in the Figures. Front Adjustment Beams 104 are positioned so the generally horizontal portion (96°) extends towards the front of the vehicle. Rear Adjustment Beams 102 are positioned so the generally horizontal portion (84°) extends towards the rear of the vehicle. The generally horizontal portions of Adjustment Beams 102 and 104 rest on top of leaf springs LS and are fixedly mounted thereto by Added U- Bolts 114. When Front Adjustment Beams 104 and Read Adjustment Beams 102 are attached to Lower Support Member 51 they compensate for the tilt of the leaf springs such that when the entire assembly is mounted on leaf springs LS, Lower Support Member 51 is maintained in a horizontal position.

The exact shape and dimensions of Front Adjustment Beam 104 and Rear Adjustment Beam 102 are designed to work with American-made full-size 1/2 -ton, 3/4- ton and 1-ton pick-up trucks. The invention can be used on other larger and smaller trucks, and other vehicles such as automobiles and trailers, the exact configuration of the invention to be based on the exact dimensions and configurations of the particular vehicle. Also, as shown in Figure 5, the hole patterns and shape of Front Adjustment Beam 104 and Rear Adjustment Beam 102 can vary. For example, holes may be vertically or horizontally arranged and Front Adjustment Beam 104 and Rear Adjustment Beam 102 can be constructed of a flat piece of 1/4" steel as shown in Figure 5, and all are contemplated within this invention.

Extenders for Vehicles with Leaf Springs below Axle.

Some vehicles, such as less-than-1 /2-ton pick-trucks, including Chevrolet SlO, Ford Ranger and Dodge Durango, have leaf springs LS below axle A of the vehicle ("full-sized" American pick-up trucks such as Chevrolet Silverado, Ford F-150 and Dodge RAM-1500, all have leaf springs LS above rear axle A). As shown in Figure 3, this embodiment of the invention includes two Front Adjustment Beam Extenders 108 and two Rear Adjustment Beam Extenders 106 fixedly attached to Front and Rear Adjustment Beam 104 and 102 respectively, as shown in the Figures, with bolts 28 and bolts 56.

One end of Front Adjustment Beam Extender 108 is angled 84° to oppositely match the 96° angle part of Front Adjustment Beam 104 so that Front Adjustment Beam

104 and Front Adjustment Beam Extender 108 are in vertical alignment. Front Adjustment Beam Extender 108 is angled at 96° at the opposite end, thereby duplicating the relative position of the invention previously discussed for trucks with leaf springs LS above the axle.

One end of Rear Adjustment Beam Extender 106 is angled 96° to oppositely match the 84° angle part of Rear Adjustment Beams 102 as shown in the Figures so Rear Adjustment Beams 102 and Rear Adjustment Beam Extenders 108 are in vertical alignment. Rear Adjustment Beam Extenders 106 are angled at 84° at the opposite end thereby duplicating the relative position of the invention previously discussed for trucks with leaf springs LS above the axle.

When Front and Rear Adjustment Beam Extenders 108 and 106 are fixedly mounted on top of leaf springs LS as shown in the figures, Lower Support Member 51 is aligned horizontally.

Fixed Width Embodiment

In an alternative embodiment, Adjustable Lower Support Assembly 48 can be made rigid or fixed-in-place described herein as Lower Support Assembly 48' in which case the exact configuration is manufactured to precisely match the exact geometry and configuration of leaf spring LS, axle A, frame F and other adjacent parts of a particular vehicle. Thus there is no need for Front and Rear Adjustment Beams 104 and 102.

Figures 10, 11 and 12 show Fixed Lower Support Assembly 48' comprised of Lower Support Plate 50, Front Strongback with Flange 52a' (Flange 53 at 96°) and Rear Fixed Strongback with Flange 52b' (Flange 54 at 84°), each of which has dimensions and configurations as required by each particular vehicle. Front Fixed Strongback 52a' includes Flange 53 that may be 6" to 12" wide, and 1" to 2" deep, bent at the same angle as Front Adjustment Beams 104. Rear Fixed Strongback with Flange 52b' includes Flange 54 that may be 6" to 12" wide, and 1" to 2" deep, bent at the same angle as Rear Adjustment Beam 102. Fixed Lower Support Assembly 48' rests on leaf springs LS as shown in part in Figure 11.

Variable Vehicle Height Improvement

While the preferred embodiment of the Adjustable Lower Support Assembly 48 (and 48') includes Coil Spring Housings 40a that work effectively on many vehicles, certain vehicles have different heights, causing Air Spring 30 to not operate within its most efficient height range and therefore 1/2-Circle Height Adapters 110 are disclosed. 1/2- Circle Height Adapters 1 10 consist of metal such as 10-gauge steel bent to have a semicircular cross section as shown in Figure 11. Two 1/2-Circle Height Adapters 110 rest on top of Coil Spring Housings 40a and encircle the Coil Springs 38. The 1/2-Circle Height Adapters 110 are fixedly held in place by use of Hose Clamp 112. In such vehicles as the Dodge RAM 1500, 1/2-Circle Height Adapters 110 shown in Figures 12 and 13 improve ride quality by positioning Air Springs 30 at a lower height for which Air Springs 30 are known to be stronger. The dimensions of 1/2- Circle Height Adapter 110 will vary depending on the configuration of the vehicle.

Frame Bracket Improvement

Lower Frame Bracket 64 and Upper Frame Bracket 66 have the designs shown in the Figures. When fixedly mounted together, there is no interference with brake lines that occurs on some vehicles such as a Dodge RAM 1500.

The preferred embodiment of Upper Support Member 21 is shown in Figures 1, 4, 5, 6, 12 and 13 etc. and is made of metal such as 10 gauge steel plate.

The preferred embodiment of Lower Frame Bracket 64 is shown in Figures 1 and 13. and is made of metal such as 10 gauge steel plate.

The preferred embodiment of Upper Frame Bracket 66 is shown in Figures 1 and 13 and is made of metal such as 10 gauge steel plate.

The present invention is intended as a retro-fit for existing vehicles. While this device fits most American-made 1 /2-ton, 3/4-ton and 1-ton pick-up trucks, it can be useful in other vehicles including but not limited to non-American-made trucks, vans, automobiles and any vehicle that has a leaf spring suspension by changing the dimensions and shapes of the parts based on the exact dimensions, weight and carry capacity of the vehicle. The invention can also be incorporated into new vehicles and

determining the exact configuration and size of various pieces required for the particular vehicle and separate pieces provided herein could be incorporated into one of at least the vehicle frame, chassis and body.

The various dimensions included in the various drawings and figures contained in this application are preferred embodiments for the specific application stated herein, to wit, American 1/2 -ton pick-up trucks. However, the adaptation of the invention for different and other vehicles requiring other sizes and dimensions are all intended to be included within the scope of the invention. Therefore the statement of specific dimensions is by way of example and not by way of limitation.

While the present invention has been described in conjunction with preferred embodiments and variations thereof, one of ordinary skill after reviewing the foregoing specification will.be able to effect various changes, substitutions of equivalents and other alterations without departing from the broad concepts disclosed herein.

The embodiments disclosed in this specification are exemplary and do not limit the invention. Other embodiments can be utilized and changes can be made. As used in this specification, the singular forms "a", "an", and "the" include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to "a part" includes a plurality of such parts, and so forth. The term "comprises" and grammatical equivalents thereof are used in this specification to mean that, in addition to the features specifically identified, other features are optionally present. The term "at least" followed by a number is used herein to denote the start of a range beginning with that number (which may be a range having an upper limit or no upper limit, depending on the variable being defined). The terms "plural", "multiple", "plurality" and "multiplicity" are used herein to denote two or more than two features. Where reference is made in this specification to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously.

Throughout this specification, where adjustment is provided by slots (overlapping between two metal plates, for example, so as to provide a space for a screw or bolt to be positioned securing the two plates), overlapping holes or combinations of holes and slots of any dimension may equally be provided.

Although many examples refer to vans and trucks, the invention applies to any form of vehicle including passenger cars, and applies to after-market and retrofitted systems as well as to new equipment.

This specification incorporates by reference all documents referred to herein and all documents filed concurrently with this specification or filed previously in connection with this application, including but not limited to such documents which are open to public inspection with this specification.