Patent Publication Number: US-2023150325-A1

Title: Golf Cart Front Suspension Lift Kit

Description:
FIELD OF THE INVENTION 
     The present subject matter relates generally to lift kits for golf cart front suspensions. 
     BACKGROUND OF THE INVENTION 
     A golf cart generally includes a front suspension that connects the golf cart&#39;s frame and front wheels. The front suspension allows relative motion between the frame and front wheels. Thus, the front suspension contributes to the handling and ride quality of the golf cart. 
     A ride height of the front suspension is generally factory selected, and golf cart manufacturers frequently tune the front suspension for road or golf course conditions. Thus, the factory ride height of many golf carts is lower than preferred by some golf carts users. To increase the golf cart&#39;s ride height, a lift kit may be added to supplement or replace the factory front suspension. 
     Known lift kits have certain drawbacks. For example, certain lift kits require modifying the golf cart&#39;s frame. In particular, such lift kits can require drilling, welding or cutting the golf cart&#39;s frame, and such modifications can be labor intensive and/or require tools not available to all golf carts users. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention. 
     In an example embodiment, a front suspension lift kit for a golf cart includes a support body mountable to a frame of the golf cart. A leaf spring is mounted to the support body, and a lower swing arm is rotatably mounted to the support body. A distal end portion of the lower swing arm is coupled to a distal end portion of the leaf spring. An upper swing arm is rotatably mountable to the frame of the golf cart. A distal end portion of the upper swing arm is mountable to a shock of the golf cart. A spindle is mountable to the lower and upper swing arms at the distal end portions of the lower and upper swing arms such that the spindle is rotatable on the lower and upper swing arms. The spindle includes a mounting plate fixed on an axle of the spindle. A brake drum of the golf cart is mountable to the spindle at the mounting plate. 
     In another exemplary embodiment, a front suspension lift kit for a golf cart includes a support body mountable to a frame of the golf cart. A leaf spring mounted to the support body, and a lower swing arm is rotatably mounted to the support body. A distal end portion of the lower swing arm is coupled to a distal end portion of the leaf spring. An upper swing arm is rotatably mountable to the frame of the golf cart. A distal end portion of the upper swing arm is mountable to a shock of the golf cart. A spindle is mountable to the lower and upper swing arms at the distal end portions of the lower and upper swing arms such that the spindle is rotatable on the lower and upper swing arms. The spindle includes a mounting plate welded to an axle of the spindle. A brake drum of the golf cart is mountable to the spindle at the mounting plate. The spindle further includes a hanger extending from the mounting plate of the spindle. The hanger defines a brake cable opening. A brake cable of the golf cart is mountable to the spindle at the brake cable opening of the hanger. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures. 
         FIG.  1    is a perspective view of a front suspension lift kit for a golf cart according to an example embodiment of the present subject matter. 
         FIGS.  2  through  8    are perspective views of certain components of the example front suspension lift kit of  FIG.  1    being mounted to a frame of the golf cart. 
     
    
    
     DETAILED DESCRIPTION 
     Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a ten percent (10%) margin. 
     As may be seen in  FIGS.  1  through  8   , the present subject matter is directed to golf cart front suspension lifts. It will be understood that the golf cart front suspension lift kits described herein may be used in or with any suitable golf cart. As an example, the front suspension lift kits described herein may be used in or with a Club Car® Carryall® golf cart. Thus, the front suspension lift kits is described in greater detail below in the context of and are illustrated as suitable for use in Club Car® Carryall® golf carts. However, the present subject matter is not limited to any particular golf car model, style or arrangement. 
       FIG.  1    is a perspective view of a front suspension lift kit  100  for a golf cart  10  according to an example embodiment of the present subject matter.  FIG.  2    is a front, elevation view of front suspension lift kit  100 . Components of golf cart  10  may be factory or stock components that front suspension lift kit  100  cooperates with to adjust a ride height of golf cart  10 . As may be seen in  FIGS.  1  and  2   , golf cart  10  includes a frame  50 . Thus, frame  50  may be a factory or stock component of golf cart  10  and is not a component of front suspension lift kit  100 . In addition, one or more of a front wheel  20 , a bracket  54 , front shocks  56 , a tie rod  60 , a rack-and-pinion  70 , a wheel bearing  80 , a brake drum  90 , and a brake cable  92  may be factory or stock components that front suspension lift kit  100  cooperates with to adjust a ride height of golf cart  10 . However, it will be understood that one or more of front wheel  20 , bracket  54 , front shocks  56 , tie rod  60 , rack-and-pinion  70 , wheel bearing  80 , brake drum  90 , brake cable  92 , and other components of golf cart  10  may be replaced, e.g., with a performance part. However, such components may not form part of front suspension lift kit  100  in certain example embodiments. As discussed in greater detail below, front suspension lift kit  100  may be mounted to or on the existing components of golf cart  10 , including frame  50 , to adjust the ride height of golf cart  10 . 
     As may be seen in  FIG.  1   , front suspension lift kit  100  includes a support body  110 , a leaf spring  120 , a pair of lower swing arms  130 , a pair of upper swing arms  140 , and a pair of spindles  150 . Lower swing arms  130  and upper swing arms  140  may also be referred to as A-arms herein. Support body  110  and upper swing arms  140  are mountable to golf cart  10 , e.g., frame  50  of golf cart  10 , and may collectively form a support assembly for mounting additional components of front suspension lift kit  100  to golf cart  10 .  FIGS.  3  and  4    show support body  110  and upper swing arms  140  being mounted to frame  50  of golf cart  10 . Mounting of support body  110  to frame  50  of golf cart  10  is described in greater detail below in the context of  FIG.  3   , and mounting of upper swing arms  140  to frame  50  of golf cart  10  is described in greater detail below in the context of  FIG.  4   . 
     As shown in  FIG.  2   , leaf spring  120  and lower swing arms  130  may be mounted to support body  110 . For example, support body  110  may include a top or support plate  112 , and leaf spring  120  and lower swing arms  130  may be mounted to top plate  112  at lower surface  114  of top plate  112 . Moreover, leaf spring  120  may be mounted top plate  112  at a middle portion of leaf spring  120 . Thus, e.g., distal end portions  122  of leaf spring  120  may be cantilever and spaced from support body  110 . Lower swing arms  130  may be rotatably mounted to support body  110 . Moreover, lower swing arms  130  may be rotatable about a rotational axis X1 relative to support body  110 . As an example, proximal end portions  132  of lower swing arms  130  may be rotatable mounted to top plate  112  at brackets  118  on lower surface  114  of top plate  112 . An upper surface  116  of top plate  112  may be positioned opposite lower surface  114  of top plate  112  on top plate  112 . 
     Distal end portions  134  of lower swing arms  130  may move relative to proximal end portions  132  of lower swing arms  130  mounted to support body  110 . For instance, as discussed in greater detail below, support body  110  may be mounted to frame  50  of golf cart  10 . During driving of golf cart  10 , lower swing arms  130  may rotate relative to support body  110  in order to provide suitable ride quality for golf cart  10 . As shown in  FIG.  2   , front suspension lift kit  100  may also include a pair of struts  160 . Struts  160  may extend between leaf spring  120  and lower swing arms  130 . Moreover, struts  160  may extend between and connect distal end portions  134  of lower swing arm  130  and distal end portions  122  of leaf springs  120 . Struts  160  may thus couple leaf spring  120  and lower swing arms  130 , e.g., such that leaf spring  120  suspends and supports lower swing arms  130  when front suspension lift kit  100  is mounted on golf cart  10 . Leaf spring  120  may also be positioned between lower and upper swing arms  130 ,  140  when front suspension lift kit  100  is mounted on golf cart  10 . 
     Installation of support body  110  and upper swing arms  140  to frame  50  of golf cart  10  will now be described with reference to  FIGS.  3  and  4   . As shown in  FIG.  3   , support body  110  may be positioned on a bottom of frame  50 . For example, upper surface  116  of top plate  112  may be positioned on the bottom of frame  50 , e.g., at a location where a stock or factory leaf spring is mounted to frame  50 . Bolts  52  used to mount the stock or factory leaf spring to frame  50  may extend through and fasten top plate  112  to frame  50 , e.g., when golf cart  10  is a Club Car® Carryall® golf cart, at holes  119  ( FIG.  2   ) through top plate  112 . Thus, frame  50  need not be drilled or otherwise modified to mount support body  110  to frame  50 . 
     Turning to  FIG.  4   , upper swing arms  140  may be rotatably mounted to frame  50  of golf cart  10 , e.g., to a bracket  54  of golf cart  10 . Bracket  54  of golf cart  10  may correspond to a location on frame  50  at which stock or factory swing arms are mounted, e.g., when golf cart  10  is a Club Car® Carryall® golf cart. Proximal end portions  142  of upper swing arms  140  may be rotatable mounted to bracket  54 . Moreover, in certain example embodiments, proximal end portions  142  of upper swing arms  140  may be received between laterally spaced walls of bracket  54 . In certain example embodiments, upper swing arms  140  may be rotatable about a rotational axis X2 relative to frame  50 . The rotational axes X2 of upper swing arms  140  may be, e.g., about, parallel to the rotation axes X1 ( FIG.  2   ) of lower swing arms  130 . 
     Distal end portions  144  of upper swing arms  140  may move relative to proximal end portions  142  of upper swing arms  140  mounted to frame  50 . For instance, during driving of golf cart  10 , upper swing arms  140  may rotate relative to frame  50  in order to provide suitable ride quality for golf cart  10 . As shown in  FIG.  3   , golf cart  10  may include front shocks  56 . Front shocks  56  may be mounted to upper swing arms  140 . For instance, front shocks  56  may be mounted to mounting brackets  146  of upper swing arms  140  positioned at distal end portions  144  of upper swing arms  140 . Front shocks  56  may extend between frame  50  of golf cart  10  and upper swing arms  140 . Front shocks  56  may thus couple upper swing arms  140  to frame  50 , e.g., such that front shocks  56  suspend and support upper swing arms  140  when front suspension lift kit  100  is mounted on golf cart  10 . 
     As may be seen in  FIG.  5   , front suspension lift kit  100  may also include spindle bearings  152 . Each spindle bearing  152  may be mounted at a respective distal end portion  134 ,  144  of lower and upper swing arms  130 ,  140 . Spindles  150  are receivable between a respective pair of spindle bearings  152  on lower and upper swing arms  130 ,  140 . In particular, spindles  150  may be mounted to lower and upper swing arms  130 ,  140  with spindle bearings  152  such that spindles  150  are rotatable on spindle bearings  152  relative to lower and upper swing arms  130 ,  140 . In particular, spindles  150  may be rotatable on spindle bearings  152  about a rotational axis X3 of spindles  150 , e.g., relative to lower and upper swing arms  130 ,  140 . In certain example embodiments, the rotational axes X3 of spindles  150  may be, e.g., about, parallel to the rotation axes X1 of lower swing arms  130  and/or the rotation axes X2 of upper swing arms  140 . Lower and upper swing arms  130 ,  140  may support spindles  150 . In particular, spindles  150  may translate vertically with lower and upper swing arms  130 ,  140 , e.g., when distal end portions  134  of lower swing arms  130  and distal end portions  144  of upper swing arms  140  translate vertically during pivoting of lower and upper swing arms  130 ,  140 . Spindles  150  may also rotate relative to lower and upper swing arms  130 ,  140  in order to allow turning of the wheels of golf cart  10  mounted to spindles  150 . 
     Spindles  150  may define a length L, e.g., between top and bottom portions of spindle  150 . The length L of spindle  150  may be no less than six inches (6″) and no greater than eighteen inches (18″). Such length L of spindles  150  may assist with providing an increased ride height relative to the stock ride height of golf cart  10  while also allowing installation of both lower and upper swing arms  130 ,  140  in order 
     Spindles  150  may include a cylinder  154  and a steering arm  156 . Steering arm  156  may extend outwardly from cylinder  154  of each spindle  150 . Steering arms  156  of spindle  150  may be configured for connecting to a tie rod  60  of golf cart  10 , as shown in  FIG.  1   . Thus, e.g., steering arms  156  may be bolted to tie rod  60 . Both spindles  150  may be coupled together with tie rod  60 , e.g., such that spindles  150  rotate together. One or both of spindles  150  may also be coupled to a rack-and-pinion  70  of golf cart  10 . For example, the steering arm  156  of one of spindles  150  may provide a connection point for rack-and-pinion  70  of golf cart  10 . Thus, rack-and-pinion  70  may be coupled to such steering arm  156 , e.g., such that rack-and-pinion  70  rotates spindles  150  when a driver of golf cart  10  turns a steering wheel (not shown) of golf cart  10 . Thus, e.g., steering arms  156  may accommodate the increased ride height provided by front suspension lift kit  100  relative to the stock ride height of golf cart  10  and allow the existing steering system of golf cart  10  to connect to front suspension lift kit  100 . 
     Each spindle  150  also includes a mounting plate  158  mounted and an axle  159 . Axle  159  may extend outwardly from cylinder  154  of each spindle  150 . Axle  159  may be positioned below steering arm  156  on cylinder  154 , e.g., when spindles  150  are mounted on lower and upper swing arms  130 ,  140 . In particular, axle  159  may be positioned at or adjacent a bottom portion of spindle  150 , and steering arm  156  may be positioned at or adjacent a top portion of spindle  150 . A wheel bearing  80  ( FIG.  6   ) of golf cart  10  may be mounted on each axle  159 , and a front wheel  20  ( FIG.  9   ) of golf cart  10  may be mounted on each wheel bearing  80 . Thus, front wheels  20  may be mounted to spindles  150  on axles  159  via wheel bearings  80  on axles  159 . Axle  159  may extend outwardly from cylinder  154  along an axis of rotation for front wheel  20 . The axis of rotation of front wheel  20  on axle  159  may be oriented about perpendicular to the rotation axes X1 of lower swing arms  130  and/or the rotation axes X2 of upper swing arms  140 . 
     As noted above, each mounting plate  158  is mounted on axle  159  of a respective spindle  150 . Thus, mounting plate  158  may be fixed relative to axle  159  such that front wheel  20  on axle  159  rotates relative to both axle  159  and mounting plate  158  during driving of golf cart  10 . As an example, mounting plate  158  may be welded to axle  159 . As shown in  FIG.  6   , a brake drum  90  of golf cart  10  is mountable to spindle  150  at mounting plate  158 . For instance, mounting plate  158  may define a plurality of mounting holes  170 , a plurality of fasteners, such as bolts, may extend through brake drum  90  and mounting plate  158  to mount brake drum  90  to spindle  150 . As may be seen from the above, front suspension lift kit  100  may provide a double swing arm lift kit for a golf cart with front drum brakes, such as Club Car® Carryall® golf carts. 
     As shown in  FIG.  6   , spindle  150  may further include a hanger  172 . Hanger  172  extends from mounting plate  158  of spindle  150 . Turning to  FIG.  7   , hanger  172  may support a brake cable  92  of golf cart  10 . For instance, hanger  172  may define a brake cable opening  174 , e.g., at a distal end portion of hanger  172 . As an example, mounting holes  170  may extend through mounting plate  158  along a direction that is about perpendicular to a direction that brake cable opening  174  extends through hanger  172 . As shown in  FIG.  7   , brake cable  92  may be mountable to spindle  150  at brake cable opening  174  of hanger  172 . Brake cable  92  is coupled to brake drum  90  and is operable to actuate brake drum  90 . For instance, a driver of golf cart  10  may step on a brake pedal (not shown) of golf cart  10  in order to actuate brake drum  90  via brake cable  92 . Cylinder  154  may be positioned between hanger  172  and steering arm  156  on spindle  150 . 
     In  FIG.  7   , front suspension lift kit  100  may be mounted on golf cart  10  after connecting brake cable  92  to hanger  172 . Moreover, as shown in  FIGS.  3  through  7   : support body  110  and upper swing arms  140  are mounted to frame  50 ; leaf spring  120  and lower swing arms  130  are mounted on support body  110 , e.g., below frame  50 ; spindles  150  are mounted to lower and upper swing arms  130 ,  140 ; brake drum  90  of golf cart  10  are mounted to spindle  150  at mounting plate  158 ; and brake cables  92  are mounted to hangers  172 . With front suspension lift kit  100  mounted on golf cart  10 , front wheels  20  may be mounted, e.g., bolted, onto spindles  150 , as shown in  FIG.  8   . 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.