FIELD OF THE INVENTION

0001] This application claims priority to US Application 16/173, 261, filed October 29, 2018. The disclosure of the above application is incorporated herein by reference .

[0002] The invention relates generally to an air spring assembly having a pressure relief capability, which prevents the air spring assembly from being exposed to excessively high pressures, which may occur during road events in which partial or full compression is achieved due to high levels to suspension travel.

[QQQ3] BACKGROUND OF THE INVENTION

[0004] Suspension systems for automotive vehicles provide vehicle passengers with a more comfortable ride. Air suspension systems utilize air springs, rather than traditional coil springs, and provide different suspension qualities that may be preferable to

traditional coil spring suspensions in some vehicles .

[0005] A conventional air spring is a device that is

arranged between a vehicle body and chassis . The typical air spring has at least one working space, or cavity that is filled with compressed air generated by a compressor . The cavity filled with compressed air at least partially fills a bellow, and other surrounding cavities . There are also air suspension systems in which the air pressure is adjustable such that the ride height of the vehicle and the spring rate of each air spring may be adjusted. Some air suspension systems are used with vehicles having off-road capability.

These off-road vehicles often operate under conditions where the suspension jounce is maximized, and the pressure in each air spring increases during

compression travel. Other instances where it may be beneficial to increase the ride height of the vehicle include traveling up or down steep ramps in a parking garage. Because the air mass (which is a product of pressure and volume) in each air spring may be adjusted to increase both the ride height and the spring rate, there may be situations where the air pressure inside one or more of the air springs reaches undesirable levels when the suspension travel of one or more of the air springs is maximized. If the air spring is not equipped to accommodate an undesirable increase in pressure due to these conditions, damage to the air spring may occur.

[0006] Accordingly, there exists a need for the ability to limit the maximum pressure an air spring assembly is exposed to during vehicle travel, specifically during certain events when suspension travel is maximized, or the vehicle load is high enough to have a high spring pressure, such that damage to the air spring assembly due to excessive pressure is minimized or eliminated.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is an air spring assembly having pressure relief capability. The pressure relief function may be used as part of an air spring assembly having a single air volume, or as part of a mu11i-chamber air spring . [0009] in an embodiment where the pressure relief capability of the pressure invention is incorporated into a multi-chamber air spring, it is possible to select a spring rate which is rigid, soft, or somewhere in between. The stiffen s ring rate is achieved by reducing the air spring volume by closing either a mechanical or an electro-mechanical valve. When the air spring assembly is operating at a stiffen spring rate in combination with a setting to increase ground clearance (such that the vehicle is better suited for off-road travel), during certain road events which occur during off-road travel, the air spring assembly is compressed, and the pressure in the air spring assembly increases. In order to not exceed the safe mechanical limits of the air spring assembly, the pressure is limited to a maximum allowable value during a road event in which full compression is achieved.

The maximum pressure is determined by the desired vehicle height setting (which increases the wheel travel and hence the maximum pressure) and vehicle load .

[0010] Different types of valves may be used to control the maximum amount of pressure in the air spring assembly. In one embodiment, the valve is a mechanical valve, and in another embodiment, the valve is an electromechanical valve .

[0011] In one embodiment, the mechanical valve is opened (or the electromechanical valve is energized) based on a "cracking pressure." The cracking pressure is determined based on the mechanical limits of the air spring assembly. Once the valve is opened (or

energized), the pressure in the air spring is reduced. This facilitates the operation of the air spring assembly at higher settings to increase ground clearance of the vehicle, while allowing for pressure relief when the mechanical limit is reached.

[0012] There are several possible configurations and

modes of operations of the air suspension system incorporating pressure relief capability, according to the present invention.

[0013] Below is a list of non-limiting potential

configurations :

[0014] Scenario- 1: In a single chamber system, a valve in the compressor is opened "electronically" when the pressure in the air spring assembly is above a

predetermined maximum amount, transferring air back

[0015] Scenario-2 : In a single chamber system, the valve (either mechanically or electronically) is used to transfer air to atmosphere when the pressure in the air spring assembly is above a predetermined maximum

amount .

[0016] Scenario-3: In a multi-chamber system, the valve in the compressor is opened "electronically" when the pressure in the air spring assembly is above a

predetermined maximum amount, transferring air back into the reservoir.

[0017] Scenario-4: In a multi-chamber system, the valve (either mechanically or electronically) is used to transfer air to atmosphere when the pressure in the air- spring assembly is above a predetermined maximum amount .

[0018] Scenario-b: In a multi-chamber system, the valve (either mechanically or electronically) is used to transfer air to another chamber internally, when the pressure in the air spring assembly is above a

predetermined maximum amount. [0019] One of the advantages of incorporating the pressure relief capability of the present invention is the ability for the air spring assembly to operate at higher pressure settings, and have an overall increased range of operation without risk of mechanical damage or durability concerns. The pressure relief capability of the present invention helps to make the benefits of air suspension, such as higher ground clearance, capability for higher vehicle loads, and/or increase suspension travel, more perceivable to the end customer.

[0020] Another advantage of the pressure relief

capability of the present invention is that, with regard to the scenarios mentioned above where the air is transferred to the reservoir when e cess pressure occurs, no reduction of air mass takes place within the air spring assembly, since the air is not exhausted to atmosphere but stored in the closed system. This retains the level speed benefits of a constant air mass system and also provides increased leveling range.

When the air suspension system is configured such that the vehicle has higher ground clearance, it is highly desirable to have a stiff spring rate to improve roll stability.

[0021] In one embodiment, the present invention is an air suspension system having a maximum pressure relief function. The air suspension system includes at least one air spring assembly, and may include additional air spring assemblies, depending on the type of vehicle incorporating the air suspension system of the present invention .

[0022] The air spring assembly includes a bellow, a first cavity formed as part of the bellow, a top caP

connected to the bellow, and a second cavity formed as part of the top cap. A first valve is in fluid communication with avity and the second cavity, at least one venting valve in fluid

communication with the first valve, and a reservoir in fluid communication with the first valve.

[0023] During a first mode of operation, the air spring assembly is configured such that the venting valve is in a closed position, and when pressure in the first cavity and the second cavity is above a predetermined maximum value, the first valve is placed in an open position such that air from the first cavity and the second cavity is vented to the reservoir.

[0024] During a second mode of operation, the air spring assembly is configured such that when pressure in the first cavity and the second cavity is above a

predetermined maximum value, the first valve and the venting valve are both placed in an open position, such that air from the first cavity and the second cavity is vented to the atmosphere,

[QQ25] An air compressor is in fluid communication with first valve and the reservoir. The air compressor is used for increasing the pressure in the first cavity and the second cavity, and during the first mode of operation, air from the first cavity and the second cavity passes through the first valve, through the air compressor, and into the reservoir,

[0026] In an alternate embodiment, the air spring

assembly includes a secondary valve in fluid

communication with the first cavity and the second cavity, such that the secondary valve allows or disallows air flow between the first cavity and the second cavity. During a third mode of operation, the air spring assembly is configured such that the venting valve is in a closed position, the first valve is in a closed position, and when pressure in the first cavity is above a predetermined maximum value, the secondary valve is placed in an open opposition such that air from the first cavity is vented to the second cavity.

[0027] Further areas of applicability of the present

invention will become apparent from the detailed

description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of

illustration only and are not intended to limit the scope of the invention.

[0028] BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will become more fully

understood from the detailed description and the accompanying drawings , wherein :

[QQ3Q] Figure 1 is a perspective view of various

components of a vehicle used as part of an air

suspension system, according to embodiments of the present invent.ion;

[0031] Figure 2 is a sectional view of a first embodiment of an air spring assembly having a pressure relief function, used as part of an air suspension system, according to embodiments of the present invention;

[QQ32] Figure 3 is a diagram of a first embodiment of an air suspension system in a first mode of operation, according to embodiments of the present invention;

[0033] Figure 4 is a diagram of a first embodiment of an air suspension system in a second mode of operation, according to embodiments of the present invention;

[0034] Figure 5 is a sectional view of a second

embodiment of an air spring assembly having a pressure relief function, used as part of an air suspension system, according to embodiments of the present invention;

[0035] Figure 6 is a diagram of a second embodiment of an air suspension system in a first mode of operation, according to embodiments of the present invention;

[0036] Figure 7 is a diagram of a second embodiment of an air suspension system in a second mode of operation, according to embodiments of the present invention; and

[0037] Figure 8 is a diagram of a second embodiment of an air suspension system in a third mode of operation, according to embodiments of the present invention.

[0038] DETAILED DES CRIPTION OF THE PREFERRED EMBODIMENT

[0039] The fo11 owing description of the preferred

embodiment ( s ) i s merely exemplary in nature and is in no wav intended to limit the invention, its

application, or uses ,

[0040] A chassis of a vehicle having an air suspension system incorporating pressure relief for each air- spring assembly is shown in Figure 1 generally at 10, The air suspension system, shown generally at 12, includes an air compressor 14, which is in fluid

communication with a reservoir, shown generally at 16, and the air compressor 14 is also in fluid

communication with four air spring assemblies 18A-18D. Each of the air spring assemblies 18A-18D is used for absorbing impact during travel of the vehicle. The first air spring assembly 18A is shown in Figure 2, however, it is within the scope of the invention that the remaining air spring assemblies 18B-18D have similar components.

[0041] Referring now to Figure 2, the air spring assembly 18A includes a top cap 20, and the top cap 20 includes an outer flange 22 The air spring 18A also includes a bellow 24, which is flexible and able to change shape during vehicle travel. A free end 26 of the bellow 24 is clamped between a clamping ring 28 and a portion of the outer flange 22. The bellow 24 includes a cavity, shown generally at .30, which is generally filled with air, and is in fluid communication with another cavity, shown generally at 32, formed as part of the top cap

9 n

[0042] The top cap 20 includes an upper housing portion 34, and the upper housing portion 34 is connected to another component of a vehicle, such the frame (not shown) of the vehicle, but it is within the scope of the invention that the upper housing portion 34 may be connected to other components of the vehicle as well.

[0043] The air spring assembly 18A in this embodiment

also includes a piston 36 having an upper extension 38. The other free end 40 of the bellow 24 is clamped between the upper extension 38 and a second clamping ring 42. The piston 36 also includes a cavity, shown generally at 44, which is also generally filled with air, and is in fluid communication with the other cavities 30,32 The cavities 30,32,44 define a first volume of air, which changes during vehicle travel, as the piston 36 moves relative to the top cap 20. A portion of the bellow 24 also extends around the second clamping ring 42, and because of the pressure inside the cavities 30,32,44, a portion of the outer surface of the bellow 24 is pressed against part of the outer surface 36A of the piston 36. The outer surface 36A functions as a contour shell, which defines a portion of the shape of the bellow 24 as the bellow 24 moves during operation of the air spring assembly 18A. [0044] ¾e air spring assembly 18A also includes a gaiter

46, iown in Figure 2, which is connected to a lower cover qa ana me top cap zu, xne rower cover ¾e is also connected to the piston 36. The lower cover 48 and the gaiter 6 provide protection for the air spring assembly 10 against dirt and debris during vehicle travel .

[0045] The piston 36 is connected to another part of the suspension system of the vehicle, such as the vehicle axle 50. As the axle 50 moves from (operation of the vehicle) the piston 36 moves along the arc-shaped path indicated by the arrow 52. The piston 36 moves along the arc-shaped path 52, which corresponds to the articulation of the axle 50 relative to the rest of the vehicle, and the volume of the cavities 30,32,44 changes during vehicle travel, as the piston 36 moves along the arc-shaped path 52.

[0046] Connected to the top cap 20 is a fitting 54, which is in fluid communication with the cavities 30,32,44. Referring now to Figure 3, a schematic of the air suspension system 12 is shown, including several valves along with the air compressor 14, and the reservoir 16, which are peart of the air suspension system 12, and the fitting 54 is in fluid communication with one of the valves. More specifically, the fitting 54 (shown in Figure 2 ) is in fluid communication with a first valve 56A (shown in Figure 3), and the first valve 56A is in fluid communication with a first control valve 58A, which is part of the air compressor 14. The first valve 56A allows or prevents air flow into the cavities 30 ,32, 4. There are additi ona 1 va1ves 56B, 56C , 56D shown in Figure 3, which control the flow of air into the corresponding air volumes for each of the

additional air spring assemblies 18B, 18C, 18D, where the piston and air volume of each air spring assembly is shown schematically in Figure 3. There is also a venting valve 60 in fluid communication with each of the va1ves 56A, 56B, 56C, 56D, 58A and in f1uid

communication with the atmosphere. Each of the valves 56A, 56B, 56C, 56D is in fluid communication with both the venting valve 60 and the first control valve 58A.

[0047] The air compressor 14 also includes a second

control valve 58B, the second control valve 58B is in fluid communication with the reservoir 16, and both the control valves 58A, 58B are in fluid communication with a pump 62. While is it shown that each of the control valves 58A, 58B are part of the air compressor 14, it is within the scope of the invention that each of the control valves 58A, 58B may be located in a separate housing, in a separate location from the air compressor 14, while still performing the same function. The air compressor 14 also includes another valve 64, which is in fluid communication 'with the pump 62, the second control valve 58B, and the atmosphere.

[0048] The valves 56A, 56B, 56C, 56D, 58A, 58B, 60, 64 as

described are electromechanical solenoid type valves, which default to a closed position when they are not. energized, and change to an open position when

energized. It is also within the scope of the

invention that the valves 56A, 56B, 56C, 56D may also be mechanical valves, such as a check valve, which default to a closed position, and open when a maximum amount of pressure in the cavities 30,32,44 is reached.

[0049] During travel of the vehicle, the air compressor 14 and the valve 56A are used to configure the air pressure in the cavities 30,32,44 such that the air spring assembly 18A provides the desired ride quality, and the vehicle is traveling at. the desired ride height .

[0050] Figure 3 depicts an example of one mode of

operation of the air suspension system 12, where the air suspension system 12 is configured to provide pressure relief of the first air spring assembly 18A. Pressure relief may become necessary when the vehicle is travelling off-road, and suspension travel of the air spring assembly 18A is maximized ( i . e . , fully compressed) . During travel of the vehicle, if the pressure in the cavities 30,32,44 of the first air spring assembly 18A increases to a level above a predetermined maximum allowable amount (referred to as "cracking pressure") , in the example shown in Figure 3, the first valve 56A, and the control valves 58A, 58B are all energized, such that the first valve 56A and the control valves 58A, 58B are placed in an open position, and the remaining valves 56B, 56C, 56D, 60, 64 are in a closed position. This allows air in the cavities 30,32,44 to pass through the first valve 56A, through the first control valve 58A, the pump 62, the second control valve 58B, and into the reservoir 16. The valves 56A, 58A, 58B may be opened at any time during operation of the vehicle when the pressure in the cavities 30,32,44 of the first air spring assembly 18A is above a predetermined maximum allowable value .

[0051] A variation of the mode of operation shown in

Figure 3 , where the pressure in the cavities 30,32,34 is less than th pressure in the reservoir 16 such that overflow of air to reduce pressure is not possible. In this instance, the pump 62 is activated, such that air is prevented from flowing into the reservoir 16, but. rather the air flows from the reservoir 16 through the second control valve 58B, the pump 62, the first control valve 58A, through the first valve 567V and into trie cavities 30,32,44.

[0052] Another example of a different mode of operation of the air suspension system 12 is shown in Figure 4, where the first valve 56A and the venting valve 60 are both energized, such that the first valve 56A and the venting valve 60 are both in an open position, and the remaining valves 56B, 56C, 56D, 58A, 58B, 64 are in a closed position. This allows air in the cavities 30,32,44 to pass through the first valve 56A, through the venting valve 60, and into the atmosphere. The valves 56A, 60 may be opened at any time during operation of the vehicle when the pressure in the cavities 30,32,44 of the first air spring assembly 18A is above the

predetermined maximum allowable value.

[0053] Furthermore, the control valves 58A, 58B or the venting valve 60 may be used in combination with any of the valves 56A, 56B, 56C, 56D to control the maximum

pressure in the cavities 30,32,44 of each of the air spring assemblies 18A, 18B, 18C, 18D . Also, more than one of the valves 56A, 56B, 56C, 56D may be opened

simultaneously in combination with the control valves 58A, 58B or the venting valve 60 to provide pressure relief to one or more of the air spring assemblies 18A, 18B, 18C, 18D . In other embodiments, there may be various configurations or arrangements of valves which are able to control the maximum pressure in the cavities 30,32,44 of each of the air spring assemblies 18A, 18B, 18C, 18D, such that the air is transferred to the reservoir 16 or the atmosphere.

[0054] Another embodiment of the air spring assembly 18A is shown in Figures 5-8 , with like numbers referring to like elements. In this embodiment of the air

suspension system 12, each of the air spring assemblies 18A, 18B, 18C, 18D has two cavities that are separated by a valve, which controls the flow of air between the two cavities. The air spring assembly 18A shown in Figure 5 is a multi-chamber air spring assembly 18A, having different spring rates. A staffer spring rate is achieved by reducing the air spring volume, 'which occurs when the valve is in a closed position, and a lower spring rate is achieved when the valve is in an open position. The second embodiment of the first air spring assembly 18A is shown in greater detail in Figure 5 (and the second embodiment of the remaining air spring assemblies 18B, 18C, 18D is similar to the air spring assembly 18A shown in Figure 5), and schematics of various configurations of the air suspension system 12 are shown in Figures 6-8.

[0055] In this embodiment, instead of the piston 36,

there is a bottom cap portion 70, and the free end 40 of the bellow 24 is clamped between the clamping ring 42 and the bottom cap portion 70 as shown in Figure 5. The bottom cap portion 70 is also connected to the vehicle axle 50.

[0056] The top cap 20 in the embodiment shown in Figure 5 is also shaped differently, such that a portion of the bellow 24 is in contact with the outer surface 20A of the top cap 20. Disposed within the cavity 32 of the top cap 20 is a secondary valve 56E, and the secondary valve 56E is able to control the flow of air between the cavity 32 of the top cap:· 20 and the cavity 30 of the bellow 24, such that when the secondary valve 56E is in a closed position, the cavity 30 of the bellow 24 acts a first air volume, and the cavity 32 of the top cap 20 acts as a second air volume, and the cavities 30,32 are isolated from one another. As mentioned above the air sparing assembly 18A shown in Figure 5 a multi-chamber air spring assembly 18A, having different spring rates. A staffer spring rate is achieved by reducing the air volume, which occurs when the secondary valve 56E is in a closed position, such that only the air volume in the cavity 30 of the bellow

24 affects the spring rate of the air spring assembly 18A. A lower spring rate is achieved by increasing the air volume, which occurs when the secondary valve 56E is in an open position such that the air volume in both the cavity 32 of the top cap 20 and the cavity 30 of the bellow 24 affect the spring rate of the air spring assembly 18A. The secondary valve 56E is in fluid communication with the fitting 54, as shown in Figure 5, and the fitting 54 is in fluid communication with a first valve 56A, and the first valve 56A is in fluid communication with a first control valve 58A, similar to the previous embodiment. However, in alternate embodiments, the fitting 54 is in direct fluid

communication with the cavity 32 of the top cap 20, and the secondary valve 56E still controls fluid

communication between the cavity 32 of the top cap 20 and the cavity 30 of the bellow 24

7] During travel of the vehicle, the air compressor 14 and the valves 56A, 56E are used to configure the air pressure in the cavities 30,32, such that the air spring assembly 18A provides the desired ride quality, and the vehicle is traveling at. the desired ride height. If the secondary valve 56E is in the closed position, the ride quality and ride height is

determined by the pressure in the cavity 30 of the bellow 24 only. If the secondary valve 56E is in the open position, the ride quality and ride height is determined by the pressure in the combined volume of the cavity 30 of the bellow 24 the cavity 32 of the top

U 6P Z. J .

[0058] Referring now to Figure 6, the air suspension

system 12 according to the second embodiment is shown in a first mode of operation, where the air suspension system 12 is configured to provide pressure relief of the first air spring assembly 18A shown in Figures 5 and 6. The secondary valve 56E is normally in an o en position, in the configuration shown in Figure 6. If the pressure in the cavity 30 of the bellow 24 of the first air spring assembly 18A is above a predetermined maximum value, in the example shown in Figure 6, the first valve 56A, and the control valves 58A, 58B are all energized, such that the first valve 56A and the control valves 58A, 58B are placed in an open position, and the remaining valves 56B, 56C, 56D, 60, 64 are in a closed position . This allows air in the cavity 30 of the bellow 24 to pass through the first valve 56A, through the first control valve 58A, the pump 62 , the second control valve 58B, and into the reservoir 16.

The valves 56A, 58A, 58B may be opened at any time during operation of the vehicle when the pressure in the cavity 30 of the bellow 24 of the first air spring assembly 18A above a predetermined maximum allowable value .

[0059] Another example of a different mode of operation of the air suspension system 12 is shown in Figure 7 , where the air suspension system 12 is again configured to provide pressure relief of the first air spring assembly 18A shown in Figures 5 and 7. In this configuration, the secondary valve 56E is again in a closed position . If the pressure in the cavity 30 of the bellow 24 reaches a predetermined maximum value, in the configuration shown in Figure 7 the first valve 56A and the venting valve 60 are both energized, such that the first valve 56A and the venting valve 60 are both in an open position, and the remaining valves

56B, 56C, 56D, 58A, 58B, 64 are in a closed position. This allows air in the cavity 30 of the bellow 24 to pass through the first valve 56A, through the venting valve 60, and into the atmosphere. The valves 56A, 60 may be opened at any time during operation of the vehicle when the pressure in the cavity 30 of the bellow 24 of the first air spring assembly 18A is above the

predetermined maximum allowable value.

[0060] Referring now to Figure 8, another mode of

operation of the air suspension system 12 is shown, where the air suspension system 12 is again configured to provide pressure relief of the first air spring assembly 18A shown in Figures 5 and 8. In this

configuration, the valves 56A, 56B, 56C, 56D, 58A, 58B, 60, 64 are in a closed position. If there is excess pressure in the cavity 30 of the bellow 24 of the first air spring assembly 18A, in the example shown in Figure 8, the secondary valve 56E, is energized, such that the secondary valve 56E is placed in an open position, and the remaining valves 56A, 56B, 56C, 56D, 58A, 58B, 60, 64 are in a closed position, This allows air in the cavity 30 of the bellow 24 to pass into the cavity 32 of the top cap 20, such that the cavity 32 of the top cap 20 functions as an additional reservoir . The valves 56F, 58G, 58H may be opened at any time during operation of the vehicle when the pressure in the cavity 30 of the bellow 24 of the other air spring assemblies

18B, 18C, 18D is above the predetermined ma imum

allowable value, such that each cavity 32 of the top cap 20 of each air spring assembly 18B, 18C, 18D is able to be used as an additional reservoir . [0061] The valves 56E,56F,58G,58H in the embodiment described in Figures 5-8 are electromechanical solenoid type valves, which default to a closed position when they are not energized, and change to an open position when energized. It is also within the scope of the invention that the valves 56E, 56F, 58G, 58H may also be mechanical valves, such as a check valve, which default to a closed position, and open when the amount of pressure in the cavi ties 30,32 is above the

predetermined maximum allowable value .

[0062] The description of the invention is merely

exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention . Such variations are not to be regarded as a departure from the spirit and scope of the invention.