Abstract:
An apparatus is described for increasing a range of height adjustment of a strut suspension system. The apparatus includes multiple spacers that together allow for increased range of adjustment and ease of installation.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable. 
       FEDERAL SPONSORSHIP 
       [0002]    Not Applicable 
       JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       TECHNICAL FIELD 
       [0004]    The present invention relates to a height adjustment of a strut suspension generally, and more particularly to a spacer assembly that provides an option to raise the strut suspension to multiple distinct heights. The spacer assembly of the present invention simplifies repetitive installation and removal of the spacers without requiring disassembly of portions of the suspension or a repositioning of the drive shaft or steering column. 
       BACKGROUND 
       [0005]    Over the years vehicle manufacturers have added complexity, components, and reduced size to vehicles which has often made it challenging to replace or modify certain portions of a vehicle suspension without disassembling other components of the vehicle. For example, after complete assembly of the vehicle, it may be desirable to raise the height of the vehicle&#39;s body by adding a conventional lift kit to the vehicle suspension between the strut assemblies and other portions of the suspension. However, addition of the conventional lift kit may require disassembly or removal of portions of the suspension before the conventional lift kit may be installed. Also, after installing conventional lift kit, the user may desire to either remove the kit or add other kits, which may also require disconnecting other vehicle components. For example, elevating a shock absorber of a strut above a control arm a sufficient distance to allow installation of conventional spacers below a lower mount may prove difficult without first removing other components of the vehicle. 
         [0006]    By way of further example, although bolts attaching the strut assembly to a lower control arm of a wishbone style suspension may be initially installed with a bolt head underneath the control arm, it may be preferred to reposition the bolt to attach the strut assembly to the control arm having the bolt head above the control arm and strut lower mount. When the bolt head is positioned above the lower mount and after the strut suspension is installed, the spacing between the drive shaft and the top portion of the lower mount of the strut assembly may not be sufficient to allow removal of the bolt positioned under the drive shaft without requiring disassembly of portions of the suspension and repositioning of the drive shaft or steering column. Further, other suspension designs may not allow for adding conventional spacers between the strut and lower mount without removal or disassembly of portions of suspension components. There is accordingly a need for a spacer system that may be added or removed below the lower mount without requiring disassembly of portions of the suspensions assembly or repositioning of the drive shaft. 
       SUMMARY 
       [0007]    Embodiments according to aspects of the invention include an apparatus for adjusting a height of a strut suspension. The apparatus may include first and second plates that include channels and ridges sized to engage in a nesting or mating relationship. The nesting plates allow a user to use the first plate, second plate or multiple plates to vary the cumulative spacer height by many distinct heights. The apparatus may also include one or more bolt receiving slots that allow engagement of the plate to a bolt from a side of the plate. 
         [0008]    According to aspects of the invention each height adjustment plate may include a bolt receiving void formed in the plate that both extends through the plate from a top surface of the plate to a bottom surface of the plate and also extends from an edge of the plate into the body of the plate. The bolt receiving void may take the shape of an open ended passage, slot, guide, or other space that is void of plate material. The bolt receiving void receives an outer diameter of a selected bolt in a fitting relation within the plate. 
         [0009]    A typical strut lower mount includes two bores that align coaxially with corresponding bores extending through the control arm. Accordingly, the spacer plate includes at least one bolt receiving void that aligns coaxially with one of the concentric bores of the lower mount and control arm. Further, the spacer plate further includes an additional bolt receiving aperture that aligns coaxially with the other concentric bores of the lower mount and control arm. The bolt receiving aperture may take the form of a solid walled cylindrical bore or hole extending from an upper surface of the plate through the plate to the bottom surface of the plate. Alternatively, the bolt receiving aperture may take the form of an open ended passage, slot, guide or other void that both extends through the plate from a top surface of the plate to a bottom surface of the plate and also extends from an edge of the plate into the body of the plate. The distance between the bolt receiving aperture and bolt receiving void is selected to align with the concentric bores of a strut lower mount bracket. 
         [0010]    In use, according to aspects of the invention it is preferred to orient the bolt heads attaching the strut assembly to a lower control arm above the lower mount of the strut assembly. Prior to installing the spacer plates of the present invention it may be desirable to reposition the bolt heads to attach the strut assembly to the control arm from above the control arm and strut lower mount. Initially, reinstalling bolts from above the control arm may require disconnecting portions of the suspension and a repositioning of the drive shaft. Also, it may be desirable to select a bolt of sufficient length to allow any potential combination of spacers without removal of the bolt aligned under the drive shaft. 
         [0011]    The bolt receiving void or slot within the plate of the present invention allows the user to engage the spacer plate to the bolt aligned under the drive shaft without removal of the bolt. Once the slot is engaged to the first bolt the plate may then be pivoted, rotated or otherwise positioned to allow the user to disengage the second bolt from the control arm to allow concentric positioning and alignment of the spacer plates apertures with the control arms and lower strut mount bolt holes. After aligning the concentric apertures and bolt holes the second bolt may re-engage the lower strut mount, spacer plate and lower control arm. In this manner, at least one or more of the first and second plates may be installed between the strut lower mount bracket and a control arm of the vehicles suspension, without the need to disassemble portions of the suspension and reposition the drive shaft, to raise the body of the vehicle above the ground a select distance. Further, the bolt receiving void or slot arrangement of the present invention allows the user to frequently add and remove spacers as seasonal demands may make more or less spacers desirable, without a significantly time consuming process. 
         [0012]    In an alternative embodiment a third plate may be positioned between the strut upper mounting bracket and vehicle body to further elevate the vehicle body above the ground. In an embodiment according to aspects of the invention the first and second plates may be constructed in a u-shape and the third plate may be constructed having a cylindrical shape. The bolt receiving void may extend into the plate from an inner edge or outer edge of the u-shape to provide a locking arrangement of the plates between the control arm and lower mount once the second bolt is engaged. Those skilled in the art will recognize that the bolt receiving void may extend into the plate from an end of one of the u-shaped arms, however extending into the plate from an inner edge of the u-shaped arm is preferred. 
         [0013]    The accompanying drawings, which are incorporated in and constitute a portion of this specification, illustrate embodiments of the invention and, together with the detailed description, serve to further explain the invention. The embodiments illustrated herein are presently preferred; however, it should be understood, that the invention is not limited to the precise arrangements and instrumentalities shown. For a fuller understanding of the nature and advantages of the invention, reference should be made to the detailed description in conjunction with the accompanying drawings. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0014]    In the various figures, which are not necessarily drawn to scale, like numerals throughout the figures identify substantially similar components. 
           [0015]      FIG. 1  is a front perspective view of a portion of a suspension system in accordance with an embodiment of the invention; 
           [0016]      FIG. 2  is a left front perspective view of a portion of a wishbone suspension system of the type shown in  FIG. 1 ; 
           [0017]      FIG. 3  is a left back perspective view of a portion of the wishbone suspension system of the type shown in  FIG. 2 ; 
           [0018]      FIG. 4  is a partially disassembled outer end perspective view of a suspension system in accordance with an embodiment of the invention; 
           [0019]      FIG. 5  is a partially disassembled lower opposing end perspective view of the suspension system of the type shown in  FIG. 4 ; 
           [0020]      FIG. 6  is an upper front perspective view of the lower strut spacer combination in accordance with an embodiment of the invention; 
           [0021]      FIG. 7  is a lower front perspective view of the lower strut spacer combination of the type shown in  FIG. 6 ; 
           [0022]      FIG. 8  is a back perspective view of the lower strut spacer combination of the type shown in  FIG. 6 ; 
           [0023]      FIG. 9  is an upper end perspective view of a first lower strut spacer in accordance with an embodiment of the invention; 
           [0024]      FIG. 10  is a lower end perspective view of the first lower strut spacer of the type shown in  FIG. 9 ; 
           [0025]      FIG. 11  is an upper end perspective view of an upper strut spacer in accordance with an embodiment of the invention; 
           [0026]      FIG. 12  is a lower end perspective view of the upper strut spacer of the type shown in  FIG. 11 ; 
           [0027]      FIG. 13  is an upper end perspective view of the second lower strut spacer in accordance with an embodiment of the invention; and 
           [0028]      FIG. 14  is a lower end perspective view of the second lower strut spacer of the type shown in  FIG. 13 . 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    The following description provides detail of various embodiments of the invention, one or more examples of which are set forth below. Each of these embodiments are provided by way of explanation of the invention, and not intended to be a limitation of the invention. Further, those skilled in the art will appreciate that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. By way of example, those skilled in the art will recognize that features illustrated or described as part of one embodiment, may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention also cover such modifications and variations that come within the scope of the appended claims and their equivalents. 
         [0030]    The strut suspension spacer assembly of the present invention includes a combination spacer  10  comprising a first spacer  12  and second spacer  14 . The first and second spacers  12  and  14  have varying thicknesses and engage in a nesting or mating relation. The first and second spacers may be used individually or together to provide many optional spacer adjustment heights. The spacer assembly may further include a third upper spacer  16 . The lower spacers of the present invention are described herein positioned between a lower control arm of a wishbone suspension and a mount bracket of a shock absorber of the strut suspension. Those skilled in the art will appreciate that the spacers may be used with other suspensions and struts having varying configurations. Further, the shape of the upper and lower spacers may be modified as necessary to cooperate with the configuration of the mounting brackets of the strut. 
         [0031]    Turning attention now to the Figures, the strut suspension spacers of the present invention will be described in greater detail.  FIGS. 1-5  illustrates the positioning of the lower strut spacer combination  10  and third spacer  16  in a vehicle suspension system  20 . Without limitation intended, the vehicle suspension  20  shown is of a wish bone type that generally includes an upper control arm  22 , lower control arm  30  and a sway bar  48  coupling a left and right suspensions. The upper control arm is shown including a camber adjustment with indicia  24  and toe adjustment markings at  26 . A wheel or steering knuckle (not shown) is coupled to the lower control arm  30  and upper control arm  22  via the lower ball joint  52  and upper ball joint  54 . The end of the upper control arm that couples to the wheel knuckle is designated at  64 . The stabilizer bar  48  is coupled to stabilizer link  50  which is coupled to the lower arm  30  at the stabilizer mount aperture  36  formed in lower control arm  30 . Ends  58  of the control arms  22  and  32  include bolt receiving inserts  60  that enable coupling of the control arms to the vehicle frame. Each strut suspension  20  includes a coil spring  38  and shock absorber  40 . The lower control arm includes apertures  32  adapted to receive mounting bolts that fasten lower mount  44  of the shock absorber  40  to the lower control arm  30 . An upper mount and bearing assembly  42  is shown that enables the fastening of the top end of the strut to the vehicle body. 
         [0032]      FIGS. 6-8  illustrate a lower strut spacer combination  10 . The strut spacers  10  include a first spacer  12  and second spacer  14 . The first spacer  12  includes bolt aperture  82  and bolt slot  84 . Similarly, the second spacer  14  includes bolt aperture  102  and bolt slot  104 . Channel  90  in the first spacer  12  is adapted to receive ridge  110  of the second spacer. Those skilled in the art will appreciate that the spacer combination  10  may be comprised of multiple first spacers  12  or multiple second spacers  14  to provide further height adjustability. 
         [0033]    With reference to  FIGS. 9 and 10  the first spacer  12  is shown in greater detail. The first spacer includes bolt receiving aperture  82  and bolt receiving slot  84  extending from top planar surface  86  to bottom planar surface  88 . A channel is formed in the bottom planar surface  88 . The spacer  12  is formed in a u-shape  80  with the aperture  82  positioned in one of the free ends of the u-shape and the slot  84  positioned in the opposing free end of the u-shape. The orientation of the slot relative to the free end will determine whether the spacer is best suited for installation on the left or right side suspension  20 . Indicia  92  provides an indication to the user which suspension (left or right) the spacer should be installed. Those skilled in the art will appreciate that a combination of a first “left” spacer and second “right” spacer provides still further height adjustability. 
         [0034]    With reference to  FIGS. 11 and 12  the third spacer  16  is shown having a concentric cylindrical shape  120 . Apertures  122  and slits  124  are spaced about the spacer and extend from a top planar surface  126  through the spacer to bottom planar surface  128 . The apertures are spaced to receive and couple to the upper mount and bearing assembly  42 . 
         [0035]    With reference to  FIGS. 13 and 14  the second spacer  14  is shown in greater detail. The second spacer includes bolt receiving aperture  102  and bolt receiving slot  104  extending from top planar surface  106  to bottom planar surface  108 . A ridge  110  extends from the bottom planar surface  108  and may be formed as a single continuous ridge (as shown) or may be segmented. The spacer  14  is formed in a u-shape  100  with the aperture  102  positioned in one of the free ends of the u-shape and the slot  104  positioned in the opposing free end of the u-shape. The orientation of the slot relative to the free end will determine whether the spacer is best suited for installation on the left or right side suspension  20 . Indicia  112  provides an indication to the user which suspension (left or right) the spacer should be installed. 
         [0036]    In use, in accordance with an aspect of the invention, after first and second bolts have been installed from above the control arm as previously described, the user begins the installation or removal of one or more spacers by unloosening nuts from the first and second bolts. The shock absorber  40  may be separated from the lower control arm to allow the desired spacers to be positioned between the lower mount and lower control arm. When separating the shock absorber from the lower control arm, the bolt aligned under the drive shaft slides within the strut mount aperture  32 . The slots  84  and  102  allow the bolt to be positioned in the slots of the spacers without removing the bolt. After positioning and engaging the slot of the spacers with the first bolt, the other bolt may be inserted through the lower mount and spacer apertures  82  and  102  and the control arm aperture  32 . Once in place, both bolts may be held in place with nuts of suitable construction. 
         [0037]    In accordance with another aspect of the invention the thickness of the first spacer and second spacer may vary to provide still further height adjustability and allow the user to use either the combination  10  or one or the other spacers  12  and  14 . In this manner the user may vary the height by many select distances while only requiring the use of two spacers. Further, each spacer of the present invention may be utilized independently or may be used in combination by nesting the first and second spacers together. The user may also install the third spacer  16  to further increase the height that the vehicle body is elevated above the ground. 
         [0038]    These and various other aspects and features of the invention are described with the intent to be illustrative, and not restrictive. This invention has been described herein with detail in order to comply with the patent statutes and to provide those skilled in the art with information needed to apply the novel principles and to construct and use such specialized components as are required. It is to be understood, however, that the invention can be carried out by specifically different constructions, and that various modifications, both as to the construction and operating procedures, can be accomplished without departing from the scope of the invention. Further, in the appended claims, the transitional terms comprising and including are used in the open ended sense in that elements in addition to those enumerated may also be present. Other examples will be apparent to those of skill in the art upon reviewing this document.