Torsion spring assembly

Abstract

A torsion spring assembly comprising a first collar and a second collar rotatable about a longitudinal axis with respect to the first collar. The torsion spring assembly further includes a third collar and a fourth collar coupled to the third collar for co-rotation about the longitudinal axis. The torsion spring assembly further includes a first torsion member extending between the first collar and the third collar, a second torsion member extending between the first collar and the third collar, a third torsion member extending between the second collar and the fourth collar, and a fourth torsion member extending between the second collar and the fourth collar.

Description

[0001] TORSION SPRING ASSEMBLY

[0002] RELATED APPLICATIONS

[0003] [1] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 637,623 filed April 23, 2024, which is incorporated herein by reference in its entirety for all purposes.

[0004] TECHNICAL FIELD

[0005] [2] This disclosure relates to torsion springs and methods of manufacture. In particular, this disclosure relates to torsion springs for use in a movable barrier operator system, for example, a garage door opener system.

[0006] BACKGROUND

[0007] [3] Movable barrier operators of various kinds are known in the art. Such movable barrier operators often work in conjunction with a corresponding movable barrier such as a single panel or segmented garage door, a rolling shutter, a pivoting, swinging, or sliding gate or arm barrier, and so forth. In particular, the movable barrier operator typically responds to user inputs (often as input via a remotely located user interface) to effect selective movement of a corresponding movable barrier (for example, to transition the movable barrier back and forth between a closed and an opened position).

[0008] [4] An example prior art counterbalance mechanism will be described with reference to FIG. 1, which illustrates a vertically lifted garage door 1001, installed using methods known in the art. The garage door 1001 has rollers 1010 that run along tracks 1020 at either side of the door. The tracks 1020 guide each segment 1002, 1003, 1004, and 1005 of the door 1001 as the door 1001 is raised or lowered. The tracks comprise a horizontal portion 1021 generally parallel to the ceiling of the garage and a vertical portion 1022 generally parallel to the door opening. The segments 1002, 1003, 1004, and 1005 are connected to one another by hinges 1009. A shaft 1030 (also referred to as a jackshaft) is mounted above the garage door 1001. Cables 1032 attach at either side of the bottom of the garage door 1001 and run vertically along the sides of the garage door 1001. The cables 1032 are spooled around drums 1040 at either end of the shaft 1030. The interaction of the cables and the drums cause the shaft to rotate as the garage door is raised or lowered. As the door 1001 lowers, the cables 1032 unspool from the drums 1040 and extend down with the door 1001 . Similarly, as the door 1001 is lifted, the cables re-spool around the drums 1040. A conventional torsion spring 1035 is coiled around the shaft 1030 and exerts a rotational force on the shaft 1030 such that the shaft 1030 has a tendency to re-spool the cables 1032. Through the cables 1032, the spring 1035 pulls against the weight of the door 1000, which makes it easier to raise the door 1000. In effect, the arrangement of the torsion spring 1035, shaft 1030, drums 1040, and cables 1032 reduce the weight of the door 1000.

[0009] [5] A garage door opener 1050 lifts and lowers the garage door 1001 by pulling a carriage 1051 along a lift track 1052 using a chain, belt, or screw. The carriage 1051 is connected to the garage door 1001 through a linkage 1053. As the garage door is raised, the weight of the segments 1002, 1003, 1004, and 1005 becomes supported as they move from the vertical portion 1022 to the horizontal portion 1021 of the garage door track 1020. In this way, the force required to lift the garage door 1001 becomes less as more segments pass along the horizontal portion 1021 of the garage door track. The conventional torsion spring 1035 accommodates this decrease in the weight of the garage door 1000 because the torsion spring 1035 exerts less force as it relaxes. The torsion spring 1035 must be sized appropriately so that the reduction in its force corresponds correctly to the position of the garage door. Any one of several sizes of torsion spring 1035 could be required, based on the width of the garage door 1001 and the relative weight of the garage door 1001. For example, different springs 1035 would be required for a two-car garage than for single car garages. Likewise, wood doors are substantially heavier than foam-cored metal doors and therefore require different springs 1035. Because this type of counterbalance mechanism is a commonly installed system, there is a need for counterbalance mechanisms that can be retrofitted on these types of existing movable barriers systems.

[0010] [6] Counterbalance mechanisms that rely upon conventional mechanical springs are known to have sudden failures that can be disturbing for people in the vicinity. Further, conventional mechanical springs typically have a relatively short lifespan. The mechanical springs known in the art and used to counterbalance the weight of movable barriers commonly fail after as few as 10,000 cycles. Particularly in industrial and commercial door installations, the limited lifespan of conventional mechanical springs requires frequent replacement of the springs. Replacing these mechanical springs is a labor intensive procedure that requires disassembly of the entire shaft assembly. [7] When used as counterbalance mechanisms, conventional mechanical springs require careful selection to match the weight of the door. The characteristics of the spring, such as spring constant and / or the displacement the spring is capable of, must be selected according to the weight and size of the door. Because these characteristics are fixed in a mechanical spring, manufacturers must stock a variety of springs.

[0011] SUMMARY

[0012] [8] The disclosure provides, in one aspect, an assembly comprising a first collar and a second collar rotatable about a longitudinal axis with respect to the first collar. The assembly further includes a third collar, a fourth collar coupled to the third collar for co-rotation about the longitudinal axis, a first torsion member extending between the first collar and the third collar, a second torsion member extending between the first collar and the third collar, a third torsion member extending between the second collar and the fourth collar, and a fourth torsion member extending between the second collar and the fourth collar.

[0013] [9] In some embodiments, the first collar, the second collar, the third collar, and the fourth collar are aligned with the longitudinal axis.

[0014]

[0010] In some embodiments, the second collar is fixed relative to the first collar along the longitudinal axis.

[0015]

[0011] In some embodiments, the second collar is positioned at least partially within the first collar, and the fourth collar is positioned at least partially within the third collar.

[0016]

[0012] In some embodiments, the fourth collar is moveable with respect to the third collar along the longitudinal axis.

[0017]

[0013] In some embodiments, an outer circumferential surface of the fourth collar includes a groove; and further comprising at least one ball bearing positioned within the groove.

[0018]

[0014] In some embodiments, the first torsion member extends between the first collar and the third collar along a path; wherein the path is a helix relative to the longitudinal axis; wherein the helix includes a helix angle within a range of 0 degrees and 45 degrees.

[0019]

[0015] In some embodiments, the helix wraps around the longitudinal axis in a first rotational direction, and wherein the second collar rotates relative to the first collar about the longitudinal axis in a second rotational direction, opposite the first rotational direction.

[0016] In some embodiments, the first torsion member is pre-stressed within a range of 50% to 5000% past a yield of the first torsion member.

[0020]

[0017] In some embodiments, the first torsion member is a wire having a diameter within a range 0.001 inch and 0.2 inch.

[0021]

[0018] In some embodiments, the first torsion member is at least partially positioned within a first aperture in the first collar; and wherein the first torsion member is at least partially positioned within a second aperture in the third collar.

[0022]

[0019] In some embodiments, the first torsion member is crimped to the first collar at a first end and crimped to the third collar at a second end, opposite the first end.

[0023]

[0020] In some embodiments, the second torsion member is spaced from the first torsion member.

[0024]

[0021] In some embodiments, the first torsion member and the second torsion member are part of a first plurality of torsion members extending between the first collar and the third collar; and wherein the third torsion member and the fourth torsion member are part of a second plurality of torsion members extending between the second collar and the fourth collar.

[0025]

[0022] In some embodiments, an aperture extends through the torsion spring assembly, wherein the aperture is aligned with the longitudinal axis.

[0026]

[0023] The disclosure provides, in one aspect, an assembly comprising a first collar, a second collar rotatable about a longitudinal axis with respect to the first collar, a first torsion member extending between the first collar and the second collar, a second torsion member extending between the first collar and the second collar, and an aperture extending through the assembly along the longitudinal axis between the first collar and the second collar.

[0027]

[0024] In some embodiments, the first torsion member extends between the first collar and the second collar along a path; wherein the path is a helix relative to the longitudinal axis; wherein the helix includes a helix angle within a range of 0 degrees and 45 degrees.

[0028]

[0025] In some embodiments, the helix wraps around the longitudinal axis in a first rotational direction, and wherein the second collar rotates relative to the first collar about the longitudinal axis in a second rotational direction, opposite the first rotational direction.

[0026] Tn some embodiments, the second torsion member extends between the first collar and the second collar along a second path parallel to the path.

[0029]

[0027] In some embodiments, the first torsion member is a compound torsion member.

[0030]

[0028] In some embodiments, the assembly further comprises a third collar rotatable about the longitudinal axis and a third torsion member extending between the second collar and the third collar.

[0031]

[0029] In some embodiments, the assembly further comprises a fourth collar rotatable about the longitudinal axis and a fourth torsion member extending between the third collar and the fourth collar.

[0032]

[0030] The disclosure provides, in one aspect, a system comprising: a shaft defining a longitudinal axis, a bracket, and a torsion spring assembly coupled to the shaft and the bracket. The torsion spring assembly includes a first collar coupled to the bracket; a second collar coupled to the shaft for co-rotation with the shaft about the longitudinal axis. The torsion spring assembly further includes a third collar, a fourth collar coupled to the third collar for co-rotation, a first plurality of torsion members extending between the first collar and the third collar, and a second plurality of torsion members extending between the second collar and the fourth collar.

[0033]

[0031] In some embodiments, the system further comprises a garage door opener.

[0034]

[0032] In some embodiments, the first collar, the second collar, the third collar, and the fourth collar are aligned with the longitudinal axis, and the second collar is at least partially positioned within the first collar, and wherein the fourth collar is at least partially positioned within the third collar.

[0035]

[0033] In some embodiments, the shaft extends through a center aperture of the torsion spring assembly.

[0036]

[0034] In some embodiments, the third collar is coupled to the fourth collar for co-rotation about the longitudinal axis; and wherein the fourth collar is moveable with respect to the third collar along the longitudinal axis.

[0037]

[0035] In some embodiments, the third collar and the fourth collar rotate relative to the shaft; and wherein the third collar and the fourth collar translate along the longitudinal axis relative to the shaft.

[0036] The disclosure provides, in one aspect, a system comprising a shaft defining a longitudinal axis, a bracket, and a torsion spring assembly coupled to the shaft and the bracket. The torsion spring assembly includes a first collar defining a rotation axis, a second collar rotatable about the rotation axis with respect to the first collar, a first torsion member extending between the first collar and the second collar, and a second torsion member extending between the first collar and the second collar. The system further comprises a gear set coupling the torsion spring assembly to the shaft. The rotation axis is offset from the longitudinal axis.

[0038]

[0037] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

[0039] BRIEF DESCRIPTION OF THE DRAWINGS

[0040]

[0038] These and other features, aspects, and advantages of the present technology will become better understood with regards to the following drawings. The accompanying figures and examples are provided by way of illustration and not by way of limitation.

[0041]

[0039] FIG. l is perspective view illustrating a prior art movable barrier system.

[0042]

[0040] FIG. 2 is a perspective view comparison of a conventional torsion spring and a plurality of torsion members.

[0043]

[0041] FIG. 3 is a perspective view of a movable barrier system including a shaft, a bracket, and a torsion spring assembly.

[0044]

[0042] FIG. 4 is a partial perspective cross-sectional view of the system of FIG. 3.

[0045]

[0043] FIG. 5 is a perspective view of a torsion spring assembly.

[0046]

[0044] FIG. 6 is another perspective view of the torsion spring assembly of FIG. 5.

[0047]

[0045] FIG. 7 is an exploded view of the torsion spring assembly of FIG. 5.

[0048]

[0046] FIG. 8 is an enlarged exploded partial view of one end of the torsion spring assembly of FIG. 5.

[0049]

[0047] FIG. 9 is an enlarged partial view of another end of the torsion spring assembly of FIG. 5.

[0048] FIG. 10 is a perspective cross-section of an end of the torsion spring assembly of FIG.

[0050] 5.

[0051]

[0049] FIG. 11 is a perspective view of a torsion spring assembly.

[0052]

[0050] FIG. 12A illustrates cross-sectional views of torsion members coupled to an outer collar and an inner collar before crimping.

[0053]

[0051] FIG. 12B illustrates assembled cross-sectional views of collars and torsion members according to one aspect of the disclosure.

[0054]

[0052] FIG. 13 is a perspective view of torsion members that are pre-stressed.

[0055]

[0053] FIG. 14A is a schematic representation of a torsion spring assembly including a first collar and a second collar.

[0056]

[0054] FIG. 14B is a cross-sectional view of FIG. 14A.

[0057]

[0055] FIG. 15A is a schematic representation of a torsion spring assembly including a first collar, a second collar, and a third collar.

[0058]

[0056] FIG. 15B is a cross-sectional view of FIG. 15A.

[0059]

[0057] FIG. 16A is a schematic representation of a torsion spring assembly including a first collar, a second collar, a third collar, and a fourth collar.

[0060]

[0058] FIG. 16B is a cross-sectional view of FIG. 16A.

[0061]

[0059] FIG. 17A is a schematic representation of a torsion spring assembly including a first collar, a second collar, a third collar, a fourth collar, and a fifth collar.

[0062]

[0060] FIG. 17B is a cross-sectional view of FIG. 17A.

[0063]

[0061] FIG. 18 is a schematic illustration of torsion members according to some embodiments.

[0064]

[0062] FIG. 19 is a schematic of a torsion spring assembly positioned inside of a rotating tube.

[0065]

[0063] FIG. 20 is a schematic of a torsion spring assembly positioned outside of a rotating shaft.

[0066]

[0064] FIG. 21 is a schematic of a system including a torsion spring assembly and a gearset.

[0065] Before any embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

[0067] DETAILED DESCRIPTION

[0068]

[0066] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present disclosure. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

[0069]

[0067] The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures. The singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments “comprising,” “consisting of’ and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.

[0070]

[0068] For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated.

[0071]

[0069] The term “coupled,” as used herein, is defined as “connected,” although not necessarily directly, and not necessarily mechanically. The term coupled is to be understood to mean physically, magnetically, chemically, fluidly, electrically, or otherwise coupled, connected or linked and does not exclude the presence of intermediate elements between the coupled elements absent specific contrary language.

[0070] With reference to FIG. 2, a comparison between a conventional torsion spring 2 and a plurality of torsion members 10 is illustrated. The conventional torsion spring 2 includes a single wire 6 wrapped tangentially around a center axis 8. In other words, the conventional torsion spring 2 is a single wire in bending moment wrapped tangentially around a center torsion axis.

[0072] In contrast, the present disclosure provides torsion members 10 (e g., torsion bars, torsion wires, etc.) extending longitudinally along a center axis 12. As disclosed herein, each of the torsion members 10 may be shaped as a wire, a bar, or other suitable structure. As disclosed herein, each of the torsion members 10 may be made of a high carbon steel, a stainless steel, an alloy steel, a composite, a copper alloy, a nickel alloy, or other suitable materials. In the illustrated embodiment, the torsion members 10 extend along the center axis 12 in a helical path. In the illustrated embodiment, the torsion members 10 include a first plurality of torsion members 14 and a second plurality of torsion members 16 positioned radially inward from the first plurality of torsion members 14. As disclosed herein, the torsion members 10 store torque and rotational energy for reducing net operational loads in a movable barrier system. The individual torsion members 10 advantageously allow for greater rotational movement without exceeding the material strength and are combined together in an array of torsion members to increase torque.

[0073]

[0071] With reference to FIG. 3, a system 20 includes a shaft 24 (also known as a jackshaft) defining a longitudinal axis 28. In the illustrated embodiment, the shaft 24 is rotatable about the longitudinal axis 28. The system 20 further includes a bracket 32 and a torsion spring assembly 36 coupled to the shaft 24 and the bracket 32. The bracket 32 is affixed to a wall or environment at a mounting flange 40 and is affixed to the torsion spring assembly 36 at two fingers 44 extending perpendicular to the mounting flange 40. Each of the fingers 44 includes a slot 46 to permit the torsion spring assembly 36 to be rotationally adjusted relative to the shaft 24 prior to securing the torsion spring assembly 36 to the bracket 32. In some embodiments, the spring tension adjustment is provided for at the stationary end of the torsion spring assembly 36. A tension adjustment assembly, in some embodiments, includes a capstan spring, a ratcheting pawl, a differential gear, a gear box, a disengaging clutch disk, or any combination thereof.

[0074]

[0072] In some embodiments, the system 20 further includes a garage door opener (e.g., garage door opener 1050). In some embodiments, the system 20 includes a gear box coupled to the torsion spring assembly 36. In some embodiments, the system 20 includes more than one torsion spring assemblies 36 coupled to the shaft 24 in series or parallel.

[0073] With reference to FIGS. 5-7, the torsion spring assembly 36 includes a first collar 48 and a second collar 52 positioned at least partially within the first collar 48. In the illustrated embodiment, the first collar 48 is coupled to the bracket 32. With reference to FIG. 4, a portion of the first collar 48 is supported on a bearing 56 to permit relative rotation between the first collar 48 and the shaft 24. The second collar 52 is coupled to the shaft 24 for co-rotation with the shaft 24 about the longitudinal axis 28.

[0075]

[0074] With reference to FIG. 10, the second collar 52 includes a bore 60 extending at a bore axis 64 through the second collar 52. In the illustrated embodiment, the bore axis 64 is perpendicular to the longitudinal axis 28. The bore axis 64 is configured to receive a fastener (e.g., a set screw) to rotationally lock the second collar 52 to the shaft 24 for co-rotation. In other words, the second collar 52 is connected to the shaft 24 and the first collar 48 is connected to the fixed bracket 32. In the illustrated embodiment, the first collar 48 and second collar 52 rotate independently of each other. In the illustrated embodiment, the second collar 52 is fixed relative to the first collar 48 along the longitudinal axis 28. In the illustrated embodiment, the second collar 52 is rotatable about the longitudinal axis 28 with respect to the first collar 48.

[0076]

[0075] With reference to FIGS. 7 and 8, the torsion spring assembly 36 further includes a third collar 68 and a fourth collar 72 coupled to the third collar 67 for co-rotation. In the illustrated embodiment, the fourth collar 72 is positioned at least partially within the third collar 68. In the illustrated embodiment, the first collar 48 and the second collar 52 are positioned at a first end 76 of the torsion spring assembly 36. The third collar 68 and the fourth collar 72 are positioned at a second end 80, opposite the first end 76. In the illustrated embodiment, the first collar 48, the second collar 52, the third collar 68, and the fourth collar 72 are aligned with the longitudinal axis 28. As shown in FIG. 3, the shaft 24 extends through a center aperture 84 of the torsion spring assembly 36 aligned with the longitudinal axis 28. In other words, the torsion spring assembly 36 is mounted on the shaft 24 such that the shaft 24 passes through the center aperture 84.

[0077]

[0076] With reference to FIG. 8, the third collar 68 is coupled to the fourth collar 72 for corotation about the longitudinal axis 28. In the illustrated embodiment, the fourth collar 72 is movable with respect to the third collar 68 along the longitudinal axis 28. In other words, the third collar 68 and the fourth collar 72 rotate together but slide independently in the axial direction. In some embodiments, the fourth collar and the third collar are a single monolithic (e.g., unitary) component. In the illustrated embodiment, an outer circumferential surface 88 of the fourth collar 72 includes grooves 92, and an inner circumferential surface 97 of the third collar 68 includes grooves 98. Ball bearings 96 are positioned within the grooves 92, 98. The third collar 68 and the fourth collar 72 rotate relative to the shaft 24. In the illustrated embodiment, the third collar 68 and the fourth collar 72 translate relative to the shaft 24 along the longitudinal axis 28.

[0078]

[0077] With reference to FIGS. 7 and 8, the torsion spring assembly 36 includes torsion members with a first plurality of torsion members 100 extending between the first collar 48 and the third collar 68, and a second plurality of torsion members 104 extending between the second collar 52 and the fourth collar 72. In the illustrated embodiment, the second plurality of torsion members 104 are positioned radially inward from the first plurality of torsion members 100. In some embodiments, there are more than one plurality of torsion members concentrically mounted. For example, in some embodiments, there are three sets of torsion members mounted in concentric circles. In some embodiments, there are four sets of torsion members mounted in concentric circles. In some embodiments, there is only a single set of torsion members.

[0079]

[0078] The first plurality of torsion members 100 are arranged in a circle around the longitudinal axis 28. The first plurality of torsion members 100 includes a first torsion member 100A extending between the first collar 48 and the third collar 68. In the illustrated embodiment, the first torsion member 100A is at least partially positioned within a first aperture 108 formed in the first collar 48. In the illustrated embodiment, the first torsion member 100A is at least partially positioned within a second aperture 112 formed in the third collar 68. In some embodiments, the first torsion member 100A is crimped to the first collar 48 at the first end 76 and crimped to the third collar 68 at the second end 80 (FIGS. 12A and 12B). In some embodiments, torsion members are secured to collars in a variety of ways including, but not limited to: adhesive (e.g. Loctite), solder, pressing, knurling, weaving, bent ends, radial crimped ends, tangential twisted crimp ends, welding, diecast, continuous threading, slotted ends, hex ends, press fit, or any combination thereof. In some embodiments, the first plurality of torsion members 100 and the second plurality of torsion members 104 is a single continuous wire that is wrapped between collars.

[0079] The first torsion member 100A extends between the first collar 48 and the third collar 68 along a path. In some embodiments, the path is linear and parallel to the longitudinal axis 28. In some embodiments, the path is a straight line extending parallel to the longitudinal axis 28. In the illustrated embodiment, the path is a helix relative to the longitudinal axis 28. The helix includes a helix angle within a range of approximately 0 degrees and approximately 45 degrees. In some embodiments, the helix angle is within a range of approximately 1 degree and approximately 30 degrees. In some embodiments, the helix angle is approximately 5 degrees. In some embodiments, the helix angle is approximately 10 degrees. In some embodiments, the helix angle is approximately 15 degrees. As used herein, the helix angle is the angle between the helix and the longitudinal axis 28.

[0080]

[0080] In the illustrated embodiment the helix wraps around the longitudinal axis 28 in a first rotational direction, and wherein the second collar 52 rotates relative to the first collar 48 about the longitudinal axis 28 in a second rotational direction, opposite the first rotational direction. In other words, the helix is wrapped in a direction such that actuation of the torsion spring assembly 36 tends to unwrap the helix. In other words, the torsion member extends in a helix path in an unloaded state, with the helix oriented in the opposite direction of rotation to advantageously minimize the change in length caused by rotation and loading of torsion spring assembly 36 (e.g., a reverse helix). Advantageously, the torsion spring assembly 36 provides length change management by including any one or more of the following: a reverse helix, pre rotations to minimize change in the length of the helix, a sliding coupling, a differential coaxial assembly and common floating end, coaxial springs with shorter outer spring and longer inner spring length to eliminate or minimize length change between springs during rotation. In some embodiments, the second plurality of torsion members 104 are wrapped in a helix direction opposite the helix direction of the first plurality of torsion members 100.

[0081]

[0081] In some embodiments, the first torsion member 100A is a wire having a cross- sectional diameter within a range of approximately 0.01 inch and approximately 0.1 inch. In some embodiments, the diameter is within a range of approximately 0.001 inch and approximately 0.2 inch. In some embodiments, the diameter is approximately 0.1 inch.

[0082]

[0082] In some embodiments, the first torsion member 100A is pre-stressed within a range of approximately 50% to approximately 5000% past a yield of the first torsion member 100A. In some embodiments, the torsion members are pre-stressed by twisting the torsion member past a yield to improve the usable range and peak torque. Pre-stressing the torsion members advantageously aligns the material grain (e.g., metal grain) in a twisted orientation to be aligned with the stress seen during actuation of the torsion spring assembly 36. In other words, prestressing the material of the torsion members advantageously maximizes the turns and material performance.

[0083] [83J The first plurality of torsion members 100 also includes a second torsion member 100B extending between the first collar 48 and the third collar 68. In the illustrated embodiment, the second torsion member 100B is spaced from the first torsion member 100A. In some embodiments, the second torsion member 100B is identical to the first torsion member 100A. As such, the description provided herein of the first torsion member 100A also applies equally to the second torsion member 100B or any of the first plurality of torsion members 100.

[0084]

[0084] The second plurality of torsion members 104 are arranged in a circle around the longitudinal axis 28. In the illustrated embodiment, the second plurality of torsion members 104 are positioned radially inward from and concentric with the first plurality of torsion members 100. The second plurality of torsion members 104 includes a third torsion member 104A extending between the second collar 52 and the fourth collar 72, and a fourth torsion member 104B extending between the second collar 52 and the fourth collar 72. In the illustrated embodiment, the fourth torsion member 104B is spaced from the third torsion member 104A. In some embodiments, the fourth torsion member 104B is identical to the third torsion member 104A. As such, description provided herein of the third torsion member 104A also applies equally to the fourth torsion member 104B or any of the second plurality of torsion members 104. In the illustrated embodiment, the second plurality of torsion members 104 form a spring inside of a spring formed by the first plurality of torsion members 100 (e.g., more than one coaxial spring formed but more than one set of torsion members). In some embodiments, the second plurality of torsion members 104 is formed as a continuation of the first plurality of torsion members 100 (e.g., a continuous wire weave).

[0085]

[0085] The torsion spring assembly 36 has several advantages over the conventional spring design. The torsion spring assembly 36 reduces weight, increases cycle life, and decreases the overall size compared to convention designs. The torsion spring assembly 36 advantageously has the stationary and the rotating end of the spring on the same side. The torsion spring assembly 36 provides improved sound quality because the conventional design has coils rubbing on each other. The torsion spring assembly 36 also provides improved utilization of material (e.g., a higher yield strength in a smaller diameter wire, and better utilization of material in torsion versus bending moment).

[0086]

[0086] In some embodiments, the torsion spring assembly 36 has three times the cycle life of a conventional spring. In some embodiments, an 8% stress reduction is achieved due to improved Seely & Smith curvature ratio for bending moment. Advantageously, the individual torsion members have a more consistent process for geometry formation. Benefits of embodiments disclosed herein include: the multiple torsion members will fail incrementally such that there is no catastrophic failure; no snaking resulting from change of length; reduced noise; reduced material and increased performance.

[0087]

[0087] With reference to FIG. 11, a torsion spring assembly 210 is illustrated according to another aspect of the disclosure. The torsion spring assembly 210 includes a first collar 214 and a second collar 218 rotatable about a longitudinal axis 222 with respect to the first collar 214. In some embodiments, one of the collars 214, 218 is coupled to a shaft for co-rotation with the shaft, and the other one of the collars 214, 218 is coupled to a bracket and fixed to the surrounding environment. The torsion spring assembly 210 includes a plurality of torsion members 226 including a first torsion member 226A extending between the first collar 214 and the second collar 218, a second torsion member 226B extending between the first collar 214 and the second collar 218, and a third torsion member 226C extending between the first collar 214 and the second collar 218. The torsion spring assembly 210 includes an aperture 230 extending through the assembly along the longitudinal axis 222 between the first collar 214 and the second collar 218.

[0088]

[0088] With continued reference to FIG. 11, the first torsion member 226A extends between the first collar214 and the second collar 218 along a path. In the illustrated embodiment, the path is a helix relative to the longitudinal axis 222. The helix wraps around the longitudinal axis in a first rotational direction. The second collar 218 rotates relative to the first collar 214 about the longitudinal axis 222 in a second rotational direction, opposite the first rotational direction. The second torsion member 226B extends between the first collar 214 and the second collar 218 along a second path parallel to the path of the first torsion member 226A. The third torsion member 226C is positioned radially inward from the first torsion member 226A and the second torsion member 226B. In some embodiments, the third torsion member 226C extends along a helical path wrapped the opposite direction of the helical path of the first torsion member 226A.

[0089]

[0089] With reference to FIGS. 14A and 14B, a torsion spring assembly 310 is illustrated with a first collar 314, a second collar 318, and a plurality of torsion members 322 extending between the first collar 314 and the second collar 318.

[0090]

[0090] With reference to FIGS. 15A and 15B, a torsion spring assembly 410 is illustrated with a first collar 414, a second collar 418, and a third collar 422. A first plurality of torsion members 426 extend between the first collar 414 and the second collar 418, and a second plurality of torsion members 430 extend between the second collar 418 and the third collar 422.

[0091]

[0091] With reference to FIGS. 16A and 16B, a torsion spring assembly 510 is illustrated with a first collar 514, a second collar 518, a third collar 522, and a fourth collar 526. A first plurality of torsion members 530 extend between the first collar 514 and the second collar 518, a second plurality of torsion members 534 extend between the second collar 518 and the third collar 522, and a third plurality of torsion members 538 extend between the third collar 522 and the fourth collar 526.

[0092]

[0092] With reference to FIGS. 17A and 17B, a torsion spring assembly 610 is illustrated with a first collar 614, a second collar 618, a third collar 622, a fourth collar 626, and a fifth collar 630. A first plurality of torsion members 634 extend between the first collar 614 and the second collar 618, a second plurality of torsion members 638 extend between the second collar 618 and the third collar 622, a third plurality of torsion members 642 extend between the third collar 622 and the fourth collar 626, and a fourth plurality of torsion members 646 extend between the fourth collar 626 and the fifth collar 630. In some embodiments, the torsion spring assembly includes any number of collars, with any number sets (pluralities) of torsion members extending between collars.

[0093]

[0093] With reference to FIG. 18, a torsion spring assembly 710 includes a first collar 714, a second collar 718, and various torsion members extending therebetween according to various embodiments. In some embodiments, the first collar 714 and the second collar 718 are solid with no center aperture. A torsion member 722 is a single wire or bar that extends between the first collar 714 and the second collar 718. A torsion member 726 is a compound torsion member with a first portion 730, a second portion 734, and an intermediate member 738 positioned between the first portion 730 and the second portion 734. In other words, the first portion 730 is in series with the second portion 734. In some embodiments, each portion 730, 734 is a wire or bar. A torsion member, as referred to herein, may be a single torsion member or a compound torsion member.

[0094] [94J With continued reference to FIG. 18, a torsion member 742 is a compound torsion member with a first portion 746, a second portion 750, a third portion 754, and an intermediate member 758. The second portion 750 and the third portion 754 are in parallel and both portions extend from the second collar 718 to the intermediate member 758. A torsion member 762 is a compound torsion member comprising twisted or entwined wires or bars.

[0095]

[0095] With reference to FIG. 19, a system 810 includes a rotating tube 814 and a torsion spring assembly 818 at least partially positioned within the tube 814. A first end 822 of the torsion spring assembly 818 is fixed and a second end 826 of the torsion spring assembly 818 is drivingly coupled to the tube 814 at an inner circumferential surface 830 of the tube 814.

[0096]

[0096] With reference to FIG. 20, a system 910 includes a rotating shaft 914 and a torsion spring assembly 918 at least partially positioned around the shaft 914. A first end 922 of the torsion spring assembly 918 is fixed and a second end 926 of the torsion spring assembly 918 is drivingly coupled to the shaft 914 at an outer circumferential surface 930 of the shaft 914.

[0097]

[0097] With reference to FIG. 21, a system 1110 includes a shaft 1114 defining a longitudinal axis 1118, a torsion spring assembly 1122, and a gear set 1126 coupling the torsion spring assembly 1122 to the shaft 1114. The torsion spring assembly 1122 defines a rotation axis 1130 that is offset from the longitudinal axis 1118 of the shaft 1114. In the illustrated embodiment, the rotation axis 1130 is spaced from and parallel to the longitudinal axis 1118. In some embodiments, the torsion spring assembly is drivingly coupled to a final driven member (e.g., a jackshaft) through a gear set (e.g., transmission).

[0098]

[0098] Various features and advantages are set forth in the following claims.

Claims

CLAIMSWhat is claimed is:

1. An assembly comprising: a first collar; a second collar rotatable about a longitudinal axis with respect to the first collar; a third collar; a fourth collar coupled to the third collar for co-rotation about the longitudinal axis; a first torsion member extending between the first collar and the third collar; a second torsion member extending between the first collar and the third collar; a third torsion member extending between the second collar and the fourth collar; and a fourth torsion member extending between the second collar and the fourth collar.

2. The assembly of claim 1, wherein the first collar, the second collar, the third collar, and the fourth collar are aligned with the longitudinal axis.

3. The assembly of claim 1, wherein the second collar is fixed relative to the first collar along the longitudinal axis.

4. The assembly of claim 1, wherein the second collar is positioned at least partially within the first collar, and the fourth collar is positioned at least partially within the third collar.

5. The assembly of claim 1, wherein the fourth collar is moveable with respect to the third collar along the longitudinal axis.

6. The assembly of claim 5, wherein an outer circumferential surface of the fourth collar includes a groove; and further comprising at least one ball bearing positioned within the groove.

7. The assembly of claim 1, wherein the first torsion member extends between the first collar and the third collar along a path; wherein the path is a helix relative to the longitudinal axis; wherein the helix includes a helix angle within a range of 0 degrees and 45 degrees.

8. The assembly of claim 7, wherein the helix wraps around the longitudinal axis in a first rotational direction, and wherein the second collar rotates relative to the first collar about the longitudinal axis in a second rotational direction, opposite the first rotational direction.

9. The assembly of claim 1, wherein the first torsion member is pre-stressed within a range of 50% to 5000% past a yield of the first torsion member.

10. The assembly of claim 1, wherein the first torsion member is a wire having a diameter within a range 0.001 inch and 0.2 inch.

11. The assembly of claim 1, wherein the first torsion member is at least partially positioned within a first aperture in the first collar; and wherein the first torsion member is at least partially positioned within a second aperture in the third collar.

12. The assembly of claim 1, wherein the first torsion member is crimped to the first collar at a first end and crimped to the third collar at a second end, opposite the first end.

13. The assembly of claim 1, wherein the second torsion member is spaced from the first torsion member.

14. The assembly of claim 1, wherein the first torsion member and the second torsion member are part of a first plurality of torsion members extending between the first collar and the third collar; and wherein the third torsion member and the fourth torsion member are part of a second plurality of torsion members extending between the second collar and the fourth collar.

15. The assembly of claim 1, wherein an aperture extends through the assembly, wherein the aperture is aligned with the longitudinal axis.

16. An assembly comprising: a first collar; a second collar rotatable about a longitudinal axis with respect to the first collar; a first torsion member extending between the first collar and the second collar; a second torsion member extending between the first collar and the second collar; and an aperture extending through the assembly along the longitudinal axis between the first collar and the second collar.

17. The assembly of claim 16, wherein the first torsion member extends between the first collar and the second collar along a path; wherein the path is a helix relative to the longitudinal axis; wherein the helix includes a helix angle within a range of 0 degrees and 45 degrees.

18. The assembly of claim 17, wherein the helix wraps around the longitudinal axis in a first rotational direction, and wherein the second collar rotates relative to the first collar about the longitudinal axis in a second rotational direction, opposite the first rotational direction.

19. The assembly of claim 17, wherein the second torsion member extends between the first collar and the second collar along a second path parallel to the path.

20. The assembly of claim 16, wherein the first torsion member is a compound torsion member.

21. The assembly of claim 16, further comprising a third collar rotatable about the longitudinal axis; and a third torsion member extending between the second collar and the third collar.

22. The assembly of claim 21, further comprising a fourth collar rotatable about the longitudinal axis; and a fourth torsion member extending between the third collar and the fourth collar.

23. A system comprising: a shaft defining a longitudinal axis; a bracket; and a torsion spring assembly coupled to the shaft and the bracket; wherein the torsion spring assembly includes: a first collar coupled to the bracket; a second collar coupled to the shaft for co-rotation with the shaft about the longitudinal axis; a third collar; a fourth collar coupled to the third collar for co-rotation; a first plurality of torsion members extending between the first collar and the third collar; and a second plurality of torsion members extending between the second collar and the fourth collar.

24. The system of claim 23, further comprising a garage door opener.

25. The system of claim 23, wherein the first collar, the second collar, the third collar, and the fourth collar are aligned with the longitudinal axis; and wherein the second collar is at least partially positioned within the first collar; and wherein the fourth collar is at least partially positioned within the third collar.

26. The system of claim 23, wherein the shaft extends through a center aperture of the torsion spring assembly.

27. The system of claim 23, wherein the third collar is coupled to the fourth collar for corotation about the longitudinal axis; and wherein the fourth collar is moveable with respect to the third collar along the longitudinal axis.

28. The assembly of claim 27, wherein the third collar and the fourth collar rotate relative to the shaft; and wherein the third collar and the fourth collar translate along the longitudinal axis relative to the shaft.

29. A system comprising: a shaft defining a longitudinal axis; a bracket; a torsion spring assembly coupled to the shaft and the bracket; wherein the torsion spring assembly includes a first collar defining a rotation axis; a second collar rotatable about the rotation axis with respect to the first collar; a first torsion member extending between the first collar and the second collar; a second torsion member extending between the first collar and the second collar; and a gear set coupling the torsion spring assembly to the shaft; wherein the rotation axis is offset from the longitudinal axis.

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