Abstract:
Load stabilizing inserts for a motor vehicle. The inserts include a base plate, a top plate spaced apart from and angularly pivotable with respect to the base plate, and one or more contact plates. The insert is sized and shaped for insertion between an overload spring and a spring pack in a motor vehicle such as a pickup truck. Four load stabilizing inserts may be installed to provide stable operation of the pickup truck when loaded at or near the maximum design gross operating weight of the vehicle. During those periods when the truck is not loaded, such as when a truck camper is not installed, the load stabilizing inserts may be angularly adjusted and secured in an open, non-working position, to provide a relatively soft ride during such position.

Description:
RELATED PATENT APPLICATIONS 
     This application claims priority from prior U.S. Provisional Patent Application Ser. No. 61/643,216, filed May 4, 2012, entitled LOAD STABILIZING INSERT FOR VEHICLE SPRINGS, the disclosure of which is incorporated herein in its entirety, including the specification, drawing, and claims, by this reference. 
    
    
     STATEMENT OF GOVERNMENT INTEREST 
     Not Applicable. 
     COPYRIGHT RIGHTS IN THE DRAWING 
     A portion of the disclosure of this patent document contains material that is subject to copyright protection. The patent owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 
     TECHNICAL FIELD 
     This application relates to apparatus and methods for stabilizing motor vehicles when handling heavy loads. 
     BACKGROUND 
     Pickup trucks are frequently used as platforms on which truck campers are mounted for over-the-road use. Not infrequently, a load imposed on the suspension system of the pickup truck subsequently nears, or occasionally exceeds, the design load limits of the suspension system of the pickup truck, especially when used for carriage of a truck camper. Often, the total weight on the vehicle suspension system, considering empty weight of the vehicle, the empty weight of the truck camper, and the added weight of a truck camper, especially when outfitted with gear and supplies for camping, fishing, or hunting, results in relatively poor handling of a fully loaded pickup truck. 
     As a consequence of difficulties in handling experienced by drivers of pickup trucks carrying loaded truck campers, interest has grown in the potential for resolving such vehicle handling problems in an economical way. Similar problems exist when other motor vehicles tow trailers, particularly when heavy tongue weight is encountered. And, various motor vehicles, including pickups trucks, may experience similar problems when hauling loads other than campers. Thus, at this time, there remains a need for a load stabilizing apparatus, and a method for use of such apparatus, which could easily be affixed in an aftermarket setting to a variety of existing motor vehicles, including pickup trucks, vans, sports utility vehicles, recreational vehicles, motor homes, and even to certain commercial vehicles. Further, straightforward methods for installing and for using such load stabilizing devices on motor vehicles would be desirable. Moreover, it would be advantageous to provide such an apparatus using low cost, commonly available, and easily manufactured and assembled materials suitable for automotive suspension applications. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       Various aspects of the developments described herein will be described by way of exemplary embodiments, illustrated in the accompanying drawing figures in which like reference numerals denote like elements, and in which: 
         FIG. 1  provides a perspective view of a load stabilizing insert, showing the insert configured in a non-working or open position, with the bottom plate shown as if attached to a an overload spring which is represented by the lowermost redlines, and with the spacer plates oriented in the open position where they do not engage the lowermost spring (represented by the uppermost redlines) in a vehicle spring pack. 
         FIG. 2  provides a perspective view of a load stabilizing insert, showing the insert configured in a working or closed position, with the bottom plate shown as if attached to a an overload spring which is represented by the lowermost redlines, and with the spacer plates oriented in the closed position where they engage and provide support to the lowermost spring (represented by the uppermost redlines) in a vehicle spring pack. 
         FIG. 3  provides a side view of the load stabilizing insert as just set forth in  FIG. 1  above, showing the insert configured in a non-working or open position, with the bottom plate shown attached to an overload spring, and with the spacer plates oriented in the open position where they do not engage the lowermost spring in a vehicle spring pack. 
         FIG. 4  provides a side view of the load stabilizing insert as just set forth in  FIG. 2  above, showing the insert configured in a working or closed position, with the bottom plate shown attached to an overload spring, and with the spacer plates oriented in the closed position where they engage the lowermost spring in a vehicle spring pack. 
         FIG. 5  provides an exploded perspective view of an embodiment for a load stabilizing insert in a configuration as just described in  FIGS. 1  though  4  above, now showing various parts and pieces for construction and operation of the device, including a pivot pin in the form of a hex bolt, a plurality of spacer washers for providing vertical clearance between the bottom plate and the contact spacer plates, a locking pin and apertures in the spacer plates and the bottom plate for its operation, and a mounting bolt for attachment of the insert to the overload spring of a vehicle. 
         FIG. 6  provides an illustration of an overload spring on a vehicle, as well as an adjacent spring pack, showing preparation of the overload spring for mounting of a load stabilizing insert thereon. 
         FIG. 7  is an illustration of an overload spring on a vehicle, as well as an adjacent spring pack, showing preparation of the overload spring for mounting of a load stabilizing insert thereon, by removal of an existing or factory provided spacer or contact pad from the upper side of the overload spring. 
         FIG. 8  is an illustration of an embodiment for a load stabilizing insert in operating position, shown in the closed position with the uppermost surface of the contact spacer plates in contact with the lowermost surface of the lower spring in a vehicle spring pack, and showing how the overload spring is located above the bottom plate and below the top plate of the load stabilizing insert. 
         FIG. 9  is an illustration of an embodiment for a load stabilizing insert in non-working, open position, shown with the contact spacer plates out of position from underneath the lowermost spring in a spring pack on a vehicle, and wherein the pivot point is positioned inside of the spring pack. 
         FIG. 10  is an illustration of an embodiment for a load stabilizing insert in non-working, open position, shown with the contact spacer plates out of position from underneath the lowermost spring in a spring pack on a vehicle, and wherein the pivot point is positioned outside of the spring pack, i.e. toward the rear tire from the spring pack. 
         FIG. 11A  is top plan diagrammatic view, taken as if below a pickup truck bed, showing the location of a left spring pack and a right spring pack mounted to an axle, and further illustrating the use of a set of four load stabilizing inserts on a vehicle, and here showing in phantom lines the contact spacer plates mounted in the working, closed position, and with each of the four load stabilizing inserts installed on the outside of each of the left spring pack and of the right spring pack. 
         FIG. 11B  is top plan diagrammatic view, taken as if below a pickup truck bed, showing the location of a left spring pack and a right spring pack mounted to an axle, and further illustrating the use of a set of four load stabilizing inserts on a vehicle, and here showing in phantom lines the contact spacer plates mounted in the working, closed position, and with each of the four load stabilizing inserts installed on the inside of each of the left spring pack and of the right spring pack. 
         FIG. 12  is an illustration of an embodiment for a load stabilizing insert in a working, load accepting, closed position, illustrating an embodiment for a bottom plate, for a top plate, use of a pivot pin with spacer plates, as well as a locking pin with locking cotter pin. 
     
    
    
     The foregoing figures, being merely exemplary, contain various elements that may be present or omitted from actual apparatus that may be constructed to provide various embodiments for a load stabilizing insert, or to various configurations for installation thereof, or to methods for use thereof. An attempt has been made to draw the figures in a way that illustrates at least those elements that are significant for an understanding of the components of an embodiment for a useful load stabilizing device for motor vehicles. However, various other elements for such apparatus, or for installation and use of the same, may be utilized in order to provide a useful load stabilizing device according to the concepts disclosed herein. 
     DETAILED DESCRIPTION 
     As seen in  FIG. 4 , a load stabilizing insert  20  is provided, which when installed in sets in a selected motor vehicle  22  (portions of which are depicted in  FIGS. 6 through 11 ), dramatically improve the handling characteristics of a motor vehicle  22  (not shown), when loaded. The load stabilizing inserts  20  are especially adapted for use in pickup trucks, but the use of load stabilizing inserts  20  is not limited thereto. For example, sport utility vehicles carrying loads, or coupe utility vehicles of a design such as, or somewhat similar to that of a Chevrolet El Camino, may also benefit, given their load carrying capabilities. A variety of motor vehicles encounter similar problems when they tow trailers, particularly when heavy tongue weight is encountered. And, various motor vehicles, including pickups trucks, may experience similar problems when hauling near or at capacity loads other than truck campers. Load stabilizing inserts  20  may easily be affixed in an aftermarket setting to a variety of existing motor vehicles, including pickup trucks, vans, sports utility vehicles, recreational vehicles, motor homes, and even to certain commercial vehicles. Generally, motor vehicles  22  which may utilize load stabilizing inserts as described herein may include a rear axle, and have a left side leaf spring set LS-SS and a right side leaf spring set RS-SS as noted in  FIGS. 11A and 11B . In an embodiment, a left side leaf spring set LS-SS and a right side leaf spring set RS-SS may each include an overload spring  24  of thickness T and a spring pack  26 , as seen in  FIGS. 3 and 4 . The thickness of an overload spring  24  may vary in different motor vehicles  22 , but by way of example, and not of limitation, often a thickness T is found to be in the 0.25 inch to 0.5 inch range. In any event, motor vehicle  22  handling characteristics are changed by using the load stabilizing inserts  20  to reset the engagement point of each overload spring  24  with the accompanying spring pack  26 . In use, as seen in  FIGS. 11A and 11B , four load stabilizing inserts  20  may be provided in a set for installation in a motor vehicle  22  (not shown) having a rear axle  23 , and left side spring packs  26   L  and right side spring packs  26   R . In an embodiment, the four load stabilizing inserts  20  in a set of inserts may be provided two per driver (left, in the US) side and two per passenger (right, in the US) side, as a left side front insert  20   LF , a left side rear insert  20   LR , a right side front insert  20   RF , and a right side rear insert  20   RR . In an embodiment as illustrated in  FIG. 11A , the left side front insert  20   LF , a left side rear insert  20   LR , a right side front insert  20   RF , and a right side rear insert  20   RR  may be mounted to the outside of the left side spring packs  26   L  and right side spring packs  26   R . In an embodiment as illustrated in  FIG. 11B , the left side front insert  20   LF , a left side rear insert  20   LR , a right side front insert  20   RF , and a right side rear insert  20   RR  may be mounted to the outside of the left side spring packs  26   L  and right side spring packs  26   R . 
     As further seen in  FIGS. 1 through 4 , a load stabilizing insert  20  may be provided using one or more contact plates  30  (e.g., contact plate  30   1 , and  30   2 , etc.), which may be pivoted about a pivot pin or bolt  32 , from an open, non-working position as shown in  FIGS. 1 and 3 , to a closed, working position as shown in  FIGS. 2 and 4 . Pivot pin or bolt  32  may be secured via nut  33 , or functionally equivalent fastener system. In an embodiment, contact plates  30  (e.g., contact plate  30   1 , and  30   2 , etc.), may be provided in a tapered or generally triangular configuration, as seen in  FIG. 1 . 
     Installation is depicted in  FIGS. 6 and 7 . Starting on a passenger side of a motor vehicle  22 , the factory overload contact pad  40  may preferably be removed from the overload spring  24 . In some motor vehicles  22 , a flat head screwdriver  42  as shown in  FIG. 7  may be used to push an overload contact pad  40  upward to disengage it from the overload spring  24 . Such factory overload contact pads  40  may be saved for re-installation if the load stabilizing inserts  20  are removed. However, it should also be noted that not all spring packs are shipped by the manufacturer (whether original equipment or aftermarket products) with pre-drilled overload springs; in such cases, a kit including a plurality of load stabilizing inserts  20  may be additionally provided for such “drilling required” applications on various vehicles. Then, the overload spring may be drilled to provide a mounting device for a load stabilizing insert  20  as described herein, and otherwise, installation proceeds as described herein. In an embodiment, a kit for installation of load stabilizing inserts  20  may include two load stabilizing inserts  20 . 
     In an embodiment, a kit may be provided for stabilizing a motor vehicle having a rear axle with a left side leaf spring pack and a right side leaf spring pack. As described above, the left side leaf spring pack and right side leaf spring pack each have a lower side. Since, in some cases a motor vehicle may not be provided with overload springs from the factory, in some embodiments a kit may include a right overload spring having a lower side and a selected thickness T, which may be designated for such right overload spring as thickness T R . Such a right overload spring may be sized and shaped for installation the right side leaf spring pack. Also, in some embodiments, a kit may include a left overload spring having a lower side and a selected thickness T, which may be designated for such left overload spring as T L . In various applications, right overload spring and left overload springs may have a selected thickness T (T L  for left overload spring and T R  for the right overload spring) of about one-half inch (0.5″) or thereabouts. In many cases, the left overload spring may be sized and shaped for installation with the right side leaf spring pack. In an embodiment, such a kit may include four load stabilizing inserts  20 . 
     On some motor vehicles  22 , there may not be sufficient clearance to mount load stabilizing inserts  20  with the pivot point (in various embodiments, the pivot is provided by bolt  32 ) on the inside of spring pack  26 , due to obstructions such as exhaust pipe hangers. In some motor vehicles  22 , such obstructions may be relocated. Alternately, during installation, a pivot point such as bolt  32  may be placed on the outside of spring pack  26  (i.e., toward tire  90  as noted in  FIG. 11 ), as illustrated in  FIG. 10 . 
     Returning to  FIGS. 1 through 4 , in an embodiment, a bottom plate  44  may be placed under the overload spring  24 , and affixed thereto such as via mounting bolt  46  and accompanying nut  47 , or functionally equivalent fastener system. Then, the installer may determine how many of the contact plates ( 30   1 ,  30   2 ,  30   N , etc) may be utilized in a particular installation to bridge the gap (in the unloaded, installing condition) between the top  50  of the overload spring  24  and the bottom  52  of the spring pack  26  (see  FIG. 3 ,  4 , or  5 ). In an embodiment, a suitable number of contact plates ( 30   1 ,  30   2 , through  30   N , where N is a positive integer, etc.) may be mounted above the top plate  60 . A plate mounting bolt  62  and accompanying nut  64 , or functionally equivalent fastener system, may be used to securely join the top plate  60  with the contact plates ( 30   1 ,  30   2 , through  30   N ) which are supported above the top plate  60 . A spacer or spacers, such as a plurality of washers  66 , may be utilized to space the top plate  60  above bottom plate  44 . In an embodiment, spacers such as washers  66  may be placed around bolt  32 , to enable bolt  32  and nut  33  (or equivalent fastening system) to secure the load stabilizing device at an appropriate location. For example see  FIG. 4 , showing washers  66  spacing apart the bottom plate  44  and the top plate  60 . Once the load stabilizing insert  20  has been placed in an open, non-working (non-loadable) standby position, or alternately in a closed, working (loadable) position, a locking pin  70  and cotter pin  72  or functionally equivalent locking system may be utilized to securely locate the top plate  60  (and accompanying contact plates  30 —i.e.  30   1 ,  30   2 , through  30   N ,) at a selected angle alpha (α) with respect to bottom plate  44  (see  FIG. 12 ). 
     The cotter pin  72  prevents axial movement (i.e. in the direction of reference arrow  74  in  FIG. 5 ) of locking pin  70 . In an embodiment, the various components may be configured to provide an angle alpha (α) of ninety (90) degrees. In an embodiment, a locking pin  70  may be located at a first aperture  80  defined by first sidewalls  82  is provided in the bottom plate  44 , and a second aperture  84  defined by second sidewalls  86  in the top plate  60 . The locking pin  70  is configured for insertion through the first aperture  80  and also through the second aperture  84 , to prevent the bottom plate  44  from pivoting with respect to the top plate  60 . 
     In an embodiment, as may be seen in  FIG. 5 , contact plates  30  (e.g., first contact plate  30   1 , second contact plate  30   2 , etc., through the Nth contact plate  30   N ) may include apertures  30   1A ,  30   2A , through  30   NA , respectively, for accommodating a locking pin  70  therethrough, to thereby secure a first contact plate  30   1 , a second contact plate  30   2 , etc. (through to Nth contact plate  30   N , not shown) to the top plate  60  and to the bottom plate  44 . In each of the one or more contact plates (i.e., first contact plate  30   1 , second contact plate  30   2 , etc., through the Nth contact plate  30   N ) an interior sidewall, noted in  FIG. 5  by reference numerals  30   1As  and  30   2As  (through  30   NAs , not shown) defines the respective contact plate locking aperture interior sidewall. The top plate  60  has a top plate locking aperture  84  therein defined by interior sidewalls  86 . In an embodiment, the top plate  60  locking aperture  84  and each of the contact plate locking apertures  30   1A ,  30   2A , through  30   NA  may be configured for alignment, when the load stabilizing insert  20  is in a working position as shown in  FIG. 5 . 
     In an embodiment, load stabilizing inserts  20  may include one or more contact plates which have a beveled edge. For example, as seen in  FIG. 1 , first contact plate  30   1  has a first beveled edge  30   1B . Likewise, second contact plate  30   2  has a second beveled edge  30   2B . The first contact plate  30   1  may include a first leading edge  30   1BL . Likewise, the second contact plate  30   2  may include a second leading edge  30   2BL . Further, the first contact plate  30   1  may include a first trailing edge  30   1BT . Likewise, the second contact plate  30   2  may include a second trailing edge  30   2BT . In an embodiment, the second trailing edge  30   2BT  and the first leading edge  30   1BL  may be adjacent. In an embodiment the first beveled edge  30   1B  and a second beveled edge  30   2E  may oriented along a common plane, for example, extending in planar fashion from reference line P shown in  FIG. 1 . 
     A method of engaging or disengaging the load stabilizing inserts  20  may be practiced when the motor vehicle  22  is without payload, i.e., in a substantially empty weight condition. A change from an open, non-working position is best accomplished by setting up the motor vehicle  22  on a level surface with the front wheels chocked, and placing a floor jack under a receiver hitch until the spring packs  26  are unloaded, that is spring packs  26  on the right and left side of motor vehicle  22 . Jack stands (not shown) may be placed under a frame of motor vehicle  22  for safety purposes. If additional clearance is needed, a pry bar may be used between the overload spring  24  and the spring pack  26  to provide further separation therebetween. 
     Generally, it may not be advisable to use load stabilizing inserts  20  in conjunction with the use of snow chains or cable chains (not shown) on tires  90 , especially if the load stabilizing inserts  20  are mounted with the bolt  32  (which acts as a pivot pin) on the outside of the spring pack  26 , for example as is illustrated in  FIG. 11 . 
     In the foregoing description, numerous details have been set forth in order to provide a thorough understanding of the disclosed exemplary embodiments for providing load stabilizing inserts  20  for motor vehicles, and in particular, for pickup trucks carrying campers. However, certain of the described details may not be required in order to provide useful embodiments, or to practice selected or other disclosed embodiments. Further, the description may include, for descriptive purposes, various relative terms such as surface, adjacent, proximity, near, on, onto, and the like. Such usage should not be construed as limiting. Terms that are relative only to a point of reference are not meant to be interpreted as absolute limitations, but are instead included in the foregoing description to facilitate understanding of the various aspects of the disclosed embodiments. Various items in the apparatus and in the method(s) described herein may have been described as multiple discrete items, in turn, in a manner that is most helpful in understanding such aspects and details. However, the order of description should not be construed as to imply that such items or sequence of operations are necessarily order dependent, or that it is imperative to fully complete one step before starting another. For example, the choice of where to mount a load stabilizing insert on a particular spring pack for a given vehicle make and model may be different as regards installation particulars amongst various installers. Further, certain details of installation may not need to be performed in the precise or exact order of presentation herein. And, in different embodiments, one or more items may be performed simultaneously, or eliminated in part or in whole while other items may be added. Also, the reader will note that the phrase “an embodiment” has been used repeatedly. This phrase generally does not refer to the same embodiment; however, it may. Finally, the terms “comprising”, “having” and “including” should be considered synonymous, unless the context dictates otherwise. 
     Various aspects and embodiments described and claimed herein may be modified from those shown without materially departing from the novel teachings and advantages provided by this invention, and may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Embodiments presented herein are to be considered in all respects as illustrative and not restrictive or limiting. This disclosure is intended to cover methods and apparatus described herein, and not only structural equivalents thereof, but also equivalent structures. Modifications and variations are possible in light of the above teachings. Therefore, the protection afforded to this invention should be limited only by the claims set forth herein, and the legal equivalents thereof.