Mechanical spring

Abstract

A mechanical spring (200) comprising a resilient section (230) extending along a longitudinal axis (102). The resilient section (230) comprises a plurality of plate sections (240) provided in series along, and spaced apart from one another along, the longitudinal axis (102). A second plate section (244) in the series is provided between a first plate section (242) and a third plate section (246) in the series. Each plate section (240) is joined to an adjacent plate section (240) by a plurality of joint elements (250). The joint elements (250) provided between the first plate section (242) and the second plate section (244) are offset around the longitudinal axis (102) from the joint elements (250) provided between the second plate section (244) and the third plate section (246), so as to enable the resilient section (230) to compress and decompress in a direction along the longitudinal axis (102).

Description

[0001] MECHANICAL SPRING

[0002] The present disclosure relates to a mechanical spring.

[0003] Background

[0004] Springs are essential mechanical spring components providing force, resistance, vibration damping, energy storage and flexibility in a large variety of devices in a wide range of mechanical and industrial applications. Traditionally, springs have been manufactured from metal due to its strength and durability. However, metal springs can be prone to corrosion, fatigue, and are often heavy, which can be a disadvantage in certain applications.

[0005] Recent advancements in spring design have focused on addressing these limitations through the use of innovative materials and advanced manufacturing techniques. However, the use of alternative spring geometry has been limited due to concerns about their mechanical properties, such as strength and stiffness.

[0006] Hence a mechanical spring which is designed to optimize load distribution and stress management, resulting in improved performance characteristics such as higher load-bearing capacity and better energy absorption, is highly desirable.

[0007] Summary

[0008] According to the present disclosure there is provided an apparatus as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

[0009] Accordingly there may be provided a mechanical spring (200). The mechanical spring (200) may comprise a resilient section (230) extending along a longitudinal axis (102).

[0010] The resilient section (230) may comprise a plurality of plate sections (240) provided in series along, and spaced apart from one another along, the longitudinal axis (102) such that a second plate section (244) in the series is provided between a first plate section (242) and a third plate section (246) in the series.

[0011] Each plate section (240) may be joined to an adjacent plate section (240) by a plurality of joint elements (250). The joint elements (250) provided between the first plate section (242) and the second plate section (244) are offset around the longitudinal axis (102) from the joint elements (250) provided between the second plate section (244) and the third plate section (246), so as toenable the resilient section (230) to compress and decompress in a direction along the longitudinal axis (102).

[0012] Each joint element (250) may define a bending axis (280) which extends in a radial direction (R) with respect to the longitudinal axis (102) such that each plate section (240) is bendable around the bending axis (280) of each joint element (250) to which it is connected.

[0013] The joint elements (250) provided between adjacent plate sections (240) may be spaced apart from one another around the longitudinal axis (102).

[0014] The joint elements (250) provided between adjacent plate sections (240) may be spaced an equal distance apart from one another around the longitudinal axis (102).

[0015] The joint elements (250) provided between adjacent plate sections (240) may be each located the same distance away from the longitudinal axis (102).

[0016] The same number N of joint elements (250) may be provided between each adjacent pair of plate sections (240).

[0017] The joint elements (250) between the first plate section (242) and the second plate section (244) may be offset by a first angle (A1 ) around the longitudinal axis (102) from the joint elements (250) provided between the second plate section (244) and the third plate section (246), wherein the first angle (A1) is equal to (180 / N).

[0018] Each joint element (250) between the first plate section (242) and second plate section (244) of a first pair of adjacent plate sections (240) may be aligned with a respective joint element (250) between the third plate section (246) and a fourth plate section (248) of a second pair of adjacent plate sections (240) along a joint element alignment line (252) parallel to longitudinal axis (102).

[0019] The second plate section (244) and third plate section (246) may be unconnected along the joint element alignment line (252) such that they are free to move relative to each other along the longitudinal axis (102) in the joint element alignment line (252).

[0020] The joint elements (250) may space adjacent plate sections (240) apart by a first distance (D1), and the plate sections (240) are biased to diverge away from one another up to a second distance (D2) between joint elements (250) between the same adjacent plate sections (240).

[0021] The plate sections (240) may have a first thickness (T1) at the joint elements (250) and narrow in thickness to a second thickness (T2) between joint elements (250).

[0022] There may be provided at least two joint elements (250) between adjacent plate sections (240).

[0023] Each plate section (240) may be circular and centred on the longitudinal axis (102).Each plate section (240) may define an aperture (272) centred on the longitudinal axis (102).

[0024] Each plate section may be provided as a ring (270) centred on the longitudinal axis (102). When the number of joint elements (250) between adjacent plate sections (240) is two, the joint elements (250) may be provided diametrically opposite one another.

[0025] The joint elements (250) extend radially from a first radial distance (RD1) from the longitudinal axis (102) to a second radial distance (RD2) from the longitudinal axis (102).

[0026] The radial length of the joint elements (250) may be at least twice their thickness and / or height.

[0027] The joint elements (250) may extend from a radially inner edge (262) of the plate section (240) to a radially outer edge (264) of the plate section (240).

[0028] Each plate section (240) may extend to a constant radius about its outer circumference. The distance from the radially inner edge (262) to the radially outer edge (264) of each plate section (240) may be the same.

[0029] The mechanical spring (200) may be integrally formed from a single material.

[0030] The mechanical spring (200) may be integrally formed from a material chosen from a list comprising Thermoplastic Elastomer (TPE), Thermoplastic Polyurethane (TPU), Cast Polyurethane (elastomer), Acrylonitrile Butadiene Styrene (ABS), Polycarbonate Polybutylene Terephthalate alloy (PC PBT), Polypropylene (PP), Polyethylene (PE), Thermoplastic Vulcanizate (TPV), Vulcanised Rubber, Steel, or Aluminium

[0031] Hence there may be provided a mechanical spring which is designed to optimize load distribution and stress management, resulting in improved performance characteristics such as higher load-bearing capacity and better energy absorption.

[0032] Brief Description of the Drawings

[0033] Examples of the present disclosure will now be described with reference to the accompanying drawings, in which:

[0034] Figure 1 shows a perspective view of a mechanical spring according to the present disclosure in a compressed state;

[0035] Figure 2 shows a perspective view of a mechanical spring according to the present disclosure in a relaxed (uncompressed) state.

[0036] Figure 3 shows an alternative perspective view of a mechanical spring according to the present disclosure in a compressed state;Figure 4 shows an alternative perspective view of a mechanical spring according to the present disclosure in a relaxed (uncompressed) state;

[0037] Figure 5 shows a side view of a mechanical spring according to the present disclosure in a relaxed (uncompressed) state;

[0038] Figure 6 shows a sectional view of a mechanical spring according to the present disclosure in a relaxed (uncompressed) state;

[0039] Figure 7 shows a side view of a mechanical spring according to the present disclosure in a compressed state;

[0040] Figure 8 shows a sectional view of a mechanical spring according to the present disclosure in a compressed state;

[0041] Figure 9 shows a side view of a mechanical spring according to the present disclosure in a further compressed state;

[0042] Figure 10 shows a sectional view of a mechanical spring according to the present disclosure in a further compressed state;

[0043] Figure 11 shows a sectional view through a layer of the mechanical spring through line A- A in figure 7;

[0044] Figure 12 shows an adjacent sectional view through a layer of the mechanical spring through line B-B in figure 7; and

[0045] Figure 13 to 16 show sectional views through layers of the mechanical spring.

[0046] Detailed Description

[0047] The present disclosure relates to a mechanical spring. The present disclosure relates to a support member comprising a mechanical spring. The present disclosure relates to a resilient member. “Resilient” is taken to mean having a property of being configured to recoil or spring back into shape after bending, flexing, stretching and / or being compressed.

[0048] The mechanical spring of the present disclosure may be used in any appropriate application. By way of non-limiting example, it may be utilised in suspension systems, seat adjustments, engine components of vehicles (e.g. automobiles), impact absorbing arrangements (e.g. protection barriers), vibration dampers in equipment, mattresses, toys, switches and / or medical devices.

[0049] As illustrated in the figures, the mechanical spring 200 may comprise a resilient section 230 extending along a longitudinal axis 102. The resilient section 230 may be operable as a spring.

[0050] As illustrated in the figures, the resilient section 230 may comprise a plurality of plate sections 240 provided in series along, and spaced apart from one another along, the longitudinalaxis 102. The plurality of plate sections 240 may comprise a first plate section 242, a second plate section 244, a third plate section 246. There may also be provided a fourth plate section 248. Hence the first plate section 242, second plate section 244, third plate section 246, and (in examples where present) the fourth plate section 248 may be provided in series along the longitudinal axis 102. The series of plate sections 240 forming the resilient section 230 may comprise more than four plate sections 240.

[0051] A second plate section 244 in the series is provided between a first plate section 242 and a third plate section 246 in the series. Where a fourth plate section 248 is provided, the third plate section 246 is provided between the second plate section 244 and the fourth plate section 248. The plate sections 240, 242, 244, 246, 248 may be arranged coaxially along the longitudinal axis 102.

[0052] Each plate section 240 is a spring element. Each spring element is configured to be resilient in a direction along the longitudinal axis 102. Each spring element may be configured to be compressible and / or extendable in a direction along the longitudinal axis 102. Each spring element may be configured to flex in a direction along the longitudinal axis 102. One or more of the plate sections 240 may be curved relative to a plane which extends perpendicular to the longitudinal axis 102.

[0053] Each plate section 240 may be joined to an adjacent plate section 240 by a plurality of joint elements 250. The joint elements 250 fix the position of the plate sections 240 relative to one another. The joint elements 250 may be provided as spacers between adjacent plate sections 240, such that (at least in a relaxed state, when no force is applied to the spring 200) a clearance is maintained between the plate sections 240. Put another way, the joint elements 250 are the only features which couple the plate sections 240.

[0054] Figures 11 , 13 show a sectional view through a layer of the mechanical spring 200 through line A-A in figure 7. Figures 12, 14 shows an adjacent sectional view through a layer of the mechanical spring 200 through line B-B in figure 7. As shown, the joint elements 250 provided between the first plate section 242 and the second plate section 244 are offset around the longitudinal axis 102 from the joint elements 250 provided between the second plate section 244 and the third plate section 246. The joint elements 250 provided between the first plate section 242 and the second plate section 244 may be around the longitudinal axis 102 from the joint elements 250 provided between the second plate section 244 and the third plate section 246. Hence as shown in figures 11 to 16 (i.e. when viewed along the longitudinal axis 102) the joint elements 250 provided between the first plate section 242 and the second plate section 244 may be “between” (e.g. misaligned) with the joint elements 250 provided between the second plate section 244 and the third plate section 246. This configuration enables the resilient section 230 to compress and decompress in a direction along the longitudinal axis 102.The pattern of joint elements 250 is repeated between further plate sections 240 in the series along the longitudinal axis 102.

[0055] Hence the joint elements 250 provided between the first plate section 242 and the second plate section 244 (as shown in figures 11 , 13) are offset around the longitudinal axis 102 from the joint elements 250 provided between the second plate section 244 and third plate section 246 (as shown in figures 12, 14).

[0056] Likewise, the joint elements 250 provided between the third plate section 246 and the fourth plate section 248 (as shown in figure 15) are offset around the longitudinal axis 102 from the joint elements 250 provided between the fourth plate section 248 and the next plate section or a base member of the spring 200, as illustrated in figure 16.

[0057] As illustrated in figures 11 , 12, each joint element 250 may define a bending axis 280 which extends in a radial direction R with respect to the longitudinal axis 102 such that each plate section 240 is bendable (i.e. operable to bend) around the bending axis 280 of each joint element 250 to which is it connected. Hence the bending axis 280 of each of the joint elements 250 shown in figures 11 , 12 extends in a line across the plate section 240 through the longitudinal axis 102.

[0058] Since the joint elements 250 between different plate sections 240 are offset from one another along the length of the spring 200, the bending axes 280 defined by the joint elements 250 between the first plate section 242 and the second plate section 244 (shown in figure 11) are at an angle to the bending axes 280 defined by the joint elements 250 between the second plate section 244 and the third plate section 246 (shown in figure 12). The length L of the spring 200 may be considered to be the distance it extends along the longitudinal axis 102 (e.g. as indicated by “L” in figures). That is to say, the length L of the spring 200 at any given time may be considered to be the extent of the spring along the longitudinal axis 102.

[0059] Compression, extension, bending and flexing is enabled by spacing apart adjacent plate sections 240 between where they are joined by the joint elements 250.

[0060] The joint elements 250 provided between the same pairs of plate sections 240 may lay in a common plane, wherein the plane extends perpendicular to the longitudinal axis 102. Put another way, if the longitudinal axis 102 is defined as an x-axis such that the spring 200 extends along the x-axis, and the spring 200 also extends in a y-axis and a z-axis, where the x-axis, y-axis and z-axis are at right angles to one another, then the joint elements 250 provided between the same pairs of plate sections 240, lay in a common plane which extends through the y-axis and the z-axis (i.e. y-z plane).

[0061] As illustrated in the figures, the joint elements 250 provided between adjacent plate sections 240 (for example between the first plate section 242 and the second plate section 244 as shown in figures 11 , 13, or between the second plate section 244 and third plate section 246as shown in figures 12, 14) may be spaced apart from one another around the longitudinal axis 102.

[0062] The joint elements 250 provided between adjacent plate sections 240 (for example between the first plate section 242 and the second plate section 244 as shown in figures 11 , 13, or between the second plate section 244 and third plate section 246 as shown in figures 12, 14) may be spaced an equal distance apart from one another around the longitudinal axis 102. That is to say, the joint elements 250 provided between adjacent plate sections 240 may be spaced apart from one another by an equal angle around the longitudinal axis 102. The joint elements 250 provided between adjacent plate sections 240 may be spaced apart from one another in the same plane by an equal angle around the longitudinal axis 102.

[0063] The joint elements 250 provided between adjacent plate sections 240 (for example between the first plate section 242 and the second plate section 244 as shown in figures 11 , 13, or between the second plate section 244 and third plate section 246 as shown in figures 12, 14) may each be located the same distance away from the longitudinal axis 102. The joint elements 250 may each be located the same distance (i.e. equidistant) away from the longitudinal axis 102.

[0064] The number of joint elements 250 provided between each adjacent pair of plate sections 240 may be denoted as number N.

[0065] There may be provided at least two joint elements 250 between adjacent plate sections 240. There may be provided at least two but no more than four joint elements 250 between adjacent plate sections 240. There may be provided at least two but no more than six joint elements 250 between adjacent plate sections 240. There may be provided at least two but no more than eight joint elements 250 between adjacent plate sections 240. There may be provided at least two but no more than ten joint elements 250 between adjacent plate sections 240. There may be provided at least two but no more than twelve joint elements 250 between adjacent plate sections 240. There may be provided more than twelve joint elements 250 between adjacent plate sections 240 The number N may be an even number or an odd number.

[0066] There may be provided a different number of joint elements 250 between adjacent plate sections 240.

[0067] In the example shown in the figures, the number of joint elements 250 between adjacent plate sections 240 is two, and the joint elements 250 are provided diametrically opposite one another.

[0068] The joint elements 250 between the first plate section 242 and the second plate section 244 may be offset by a first angle A1 around the longitudinal axis 102 from the joint elements 250 provided between the second plate section 244 and the third plate section 246. The first angle A1 may be equal to 180 / N.Hence, as shown in figures 11 , 12, if there are two joint elements 250 provided between each adjacent pair of plate sections 240, then the joint elements 250 between the first plate section 242 and the second plate section 244 may be offset by 90 deg around the longitudinal axis 102 from the joint elements 250 provided between the second plate section 244 and the third plate section 246.

[0069] As illustrated in figures 1 , 2 and figures 13 to 16, each joint element 250 between the first plate section 242 and second plate section 244 of a first pair of adjacent plate sections 240 may be aligned with a respective joint element 250 between the third plate section 246 and a fourth plate section 248 of a second pair of adjacent plate sections 240 along a joint element alignment line 252 parallel to (and offset from) the longitudinal axis 102. The second plate section 244 and third plate section 246 may be unconnected along the joint element alignment line 252 (e.g. spaced apart from one another) such that they are free to move relative to each other along the longitudinal axis 102 in the joint element alignment line 252.

[0070] As illustrated in figure 2, the joint elements 250 may space adjacent plate sections 240 apart by a first distance D1. The plate sections 240 may be biased to diverge away from one another up to a second distance D2. The second distance D2 may be greater than the first distance D1. The second distance D2 may be the maximum / greatest distance between the adjacent plate sections 240. As illustrated in figure 2, the first distance D1 and the second distance D2 may be the spacing / distance in a direction parallel to the longitudinal axis 102.

[0071] The plate sections 240 may be biased to diverge away from one another up to a second distance D2 between joint elements 250 between the same adjacent plate sections 240. The plate sections 240 may be biased to diverge away from one another up to a second distance D2 at a position halfway between joint elements 250 between the same adjacent plate sections 240. The plate sections 240 may be biased to diverge away from one another up to a second distance D2 at an angular (e.g. circumferential) position halfway between joint elements 250 between the same adjacent plate sections 240. Hence adjacent plate sections 240 form a wedge or diamond shaped (e.g. rhombus shaped) space between joint elements 250.

[0072] The plate sections 240 may diverge at an angle that increases the distance between them up to a position halfway between the joint elements 250. The plate sections 240 may diverge at an angle that increases the longitudinal I axial distance between them up to a position halfway between the joint elements 250.

[0073] The plate sections 240 may diverge such that the distance between them increases between a joint element 250 and a position halfway between the joint elements 250 between the same adjacent plate sections 240. The plate sections 240 may diverge such that the longitudinal I axial distance between them increases between a joint element 250 and a position halfway between the joint elements 250 between the same adjacent plate sections 240.The plate sections 240 may be arranged such that the spacing (e.g. the longitudinal / axial distance) between the plate sections 240 increases progressively from the first distance D1 at one of the joint elements 250 to the second distance D2, and then decreases progressively to the first distance D1 at the other of the joint elements 250 between the same adjacent plate sections 240.

[0074] In some examples, one or more of the plate sections 240 may have a constant thickness. That is to say, one or more of the plate sections 240 may have a substantially uniform thickness.

[0075] As illustrated in figure 2, the plate sections 240 may have a first thickness T1 at the joint elements 250 and narrow in thickness to a second thickness T2. The second thickness T2 may be less than the first thickness T 1. The second thickness T2 may located between where the plate sections 240 are linked by joint elements 250. Hence the plate sections 240 may have a first thickness T1 at the joint elements 250 and narrow in thickness to a second thickness T2 halfway between joint elements 250.

[0076] As illustrated in figure 2, the first thickness T1 and the second thickness T2 of the plate sections 240 may be a dimension which extends in a direction parallel to the longitudinal axis 102 (e.g. the axial direction).

[0077] Each plate section 240 may be of any appropriate shape (e.g. circular, polygonal, oval, irregular etc). Each plate section 240 may be centred on the longitudinal axis 102.

[0078] In the examples shown in the figures, each plate section 240 is circular and centred on the longitudinal axis 102.

[0079] Each plate section 240 may define an aperture 272 (e.g. hollow region) which extends from a centre point centred on the longitudinal axis 102. Each plate section 240 may be provided as a ring 270 centred on the longitudinal axis 102, the aperture 272 being provided at the centre of the ring 270.

[0080] Each of the joint elements 250 may extend radially from a first radial distance RD1 from the longitudinal axis 102 to a second radial distance RD2 from the longitudinal axis 102. This is illustrated in figure 11. The joint elements 25 may thus have a radial length RL which is the difference between the second radial distance RD2 and the first radial distance RD1.

[0081] The radial length RL of the joint elements 250 may be at least twice their thickness and / or height.

[0082] As illustrated in figure 2, the joint elements 250 may have a height H1 , where the height H1 extends in a direction parallel to the longitudinal axis 102. The height H1 may be the same as the first distance D1.As illustrated in figure 2, the joint elements 250 may have a thickness T3, where the thickness T3 extends in a circumferential and / or hoop (e.g. angular) direction around the longitudinal axis 102.

[0083] The radial length RL of the joint elements 250 may be equal to or greater than the height H1 of the joint elements 250.

[0084] The radial length RL of the joint elements 250 may be at least twice their thickness T3. The radial length RL of the joint elements 250 may be at least twice their height H1. The radial length RL of the joint elements 250 may be at least twice but no more than three times their thickness T3 and / or height H1. The radial length RL of the joint elements 250 may be at least twice but no more than five times their thickness T3 and / or height H1. The radial length RL of the joint elements 250 may be at least twice but no more than ten times their thickness T3 and / or height H1. The radial length RL of the joint elements 250 may be at least twice but no more than twenty times their thickness T3 and / or height H1.

[0085] The joint elements 250 may extend from a radially inner edge 262 of the plate section 240 to a radially outer edge 264 of the plate section 240.

[0086] As illustrated in figures 11 , 12 the joint elements 250 may extend from a radially inner edge 262 of the ring 270 to a radially outer edge 264 of the ring 270.

[0087] One or more of the joint elements 250 may be configured to break at a predetermined load. This may be advantageous in some applications, for example so that at specific loading the spring will fail, thereby locking / fixing a component it supports into a secure position.

[0088] Each plate section 240 may extend to a constant radius about its outer circumference. Each ring 270 may extend to a constant radius about its outer circumference.

[0089] The distance from the radially inner edge 262 to the radially outer edge 264 of each plate section 240 may be equal.

[0090] The mechanical spring 200 may be integrally formed from a single material.

[0091] By way of non limiting example, the mechanical spring 200 may be integrally formed from a material chosen from a list comprising Thermoplastic Elastomer (TPE), Thermoplastic Polyurethane (TPU), Cast Polyurethane (elastomer), Acrylonitrile Butadiene Styrene (ABS), Polycarbonate Polybutylene Terephthalate alloy (PC PBT), Polypropylene (PP), Polyethylene (PE), Thermoplastic Vulcanizate (TPV), Vulcanised Rubber, Steel (either machined or 3d printed), Aluminium (either machined or 3d printed).

[0092] In examples in which a polymer is used, they may be either unfilled or contain mineral particles (for example Talc) or fibre (for example glass) as a filler.Figures 5 to 10 illustrate the compression of a spring 200 of the present disclosure. As illustrated, when a force F (indicated by the arrows in figures 7 to 10) is applied to the spring 200 in a direction along the longitudinal axis 102, the regions of the plate sections 240 not connected by the joint elements 250 will come closer together in compression.

[0093] When a force is applied to extend the spring 200 in a direction along the longitudinal axis 102, the regions of the plate sections 240 not connected by the joint elements 250 will move further apart in tension.

[0094] The material from which the spring 200 is made may have elastic properties, meaning it is operable return to its original shape after the compression or expansion force is removed. This elasticity allows the spring 200 to store and release energy efficiently. Hence, in both cases, when the force is released, the spring 200 will extend back to its original length. That is to say, the spring 200 generates a restoring force that opposes compression and expansion, trying to return to its original length.

[0095] When a bending force is applied, the plate sections 240 of the spring 200 deform, causing the spring 200 to curve. During bending, different parts of the spring 200 experience varying levels of stress, with one side under compression and the other under tension.

[0096] The spring 200 of the present disclosure will inherently resist twisting because of the coupling of the plate sections 240 by the joint elements 250 at a plurality of locations between each pair of adjacent plate sections 240.

[0097] The spring 200 according to the present disclosure may be manufactured by any appropriate method. By way of non-limiting example, the spring 200 may be made by injection moulding, three dimensional printing or assembled from a plurality of parts (for example plate sections and joint elements).

[0098] The device of the present disclosure addresses the limitations of existing springs designs by virtue of its structure that provides enhanced performance and reliability. The mechanical spring of the present disclosure is particularly relevant for applications in force damping applications, for example in shock absorbing applications in crash barriers, automotive, aerospace, and medical industries.

[0099] The geometry of the mechanical spring of the present disclosure is designed to optimize load distribution and stress management, resulting in improved performance characteristics such as higher load-bearing capacity, stiffness and energy absorption compared to examples of the related art.

[0100] When made from plastic or other lightweight materials, the mechanical spring of the present disclosure contributes to significant weight reduction, which is particularly beneficial in applications where minimizing weight is critical, such as in automotive and aerospace applications.In examples in which a mechanical spring of the present disclosure is made from plastic or corrosion-resistant materials, it may provide structural integrity and performance in harsh environments, reducing the need for replacement, maintenance and lubrication.

[0101] The options encompassed by the geometry of the present disclosure allows for greater customization to meet specific application requirements. This flexibility enables the production of mechanical springs (e.g. springs) with tailored properties, such as variable stiffness and damping characteristics, to suit a diverse range of needs in different applications.

[0102] The mechanical spring of the present disclosure can be efficiently produced using advanced manufacturing techniques such as 3D printing and injection moulding. This results in reduced production costs, faster prototyping, and the ability to create complex shapes that were previously difficult to achieve with traditional manufacturing methods.

[0103] The optimized design of the mechanical spring of the present disclosure reduces stress concentrations and fatigue points, enhancing the overall durability and lifespan of the mechanical spring. This leads to longer-lasting components and improved reliability.

[0104] The mechanical spring of the present disclosure is adaptable to various materials, including plastics, composites, and metals, making it suitable for a wide range of applications. This versatility ensures that the benefits of the mechanical spring may be efficacious across different industries and use cases.

[0105] The mechanical spring of the present disclosure can help in reducing noise and vibrations in mechanical systems, leading to quieter operation and improved user experience in applications such as consumer electronics and household appliances.

[0106] The improved energy storage and release characteristics of the mechanical spring of the present disclosure contribute to more efficient operation of mechanical systems, potentially leading to energy savings and reduced operational costs.

[0107] Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

[0108] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive.

[0109] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. Theinvention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), orto any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS1. A mechanical spring (200) comprising a resilient section (230) extending along a longitudinal axis (102),the resilient section (230) comprising a plurality of plate sections (240) provided in series along, and spaced apart from one another along, the longitudinal axis (102) such that a second plate section (244) in the series is provided between a first plate section (242) and a third plate section (246) in the series;each plate section (240) being joined to an adjacent plate section (240) by a plurality of joint elements (250);the joint elements (250) provided between the first plate section (242) and the second plate section (244) are offset around the longitudinal axis (102) from the joint elements (250) provided between the second plate section (244) and the third plate section (246), so as to enable the resilient section (230) to compress and decompress in a direction along the longitudinal axis (102).

2. A mechanical spring (200) as claimed in claim 1 wherein each joint element (250) defines a bending axis (280) which extends in a radial direction (R) with respect to the longitudinal axis (102) such that each plate section (240) is bendable around the bending axis (280) of each joint element (250) to which it is connected.

3. A mechanical spring (200) as claimed in claim 1 or claim 2 wherein the joint elements (250) provided between adjacent plate sections (240) are spaced apart from one another around the longitudinal axis (102).

4. A mechanical spring (200) as claimed in any one of claims 1 to 3 wherein the joint elements (250) provided between adjacent plate sections (240) are spaced an equal distance apart from one another around the longitudinal axis (102).

5. A mechanical spring (200) as claimed in any one of claims 1 to 4 wherein the joint elements (250) provided between adjacent plate sections (240) are each located the same distance away from the longitudinal axis (102).

6. A mechanical spring (200) as claimed in any one of claims 1 to 5 wherein the same number N of joint elements (250) are provided between each adjacent pair of plate sections (240).

7. A mechanical spring (200) as claimed in claim 6 wherein the joint elements (250) between the first plate section (242) and the second plate section (244) are offset by a first angle (A1) around the longitudinal axis (102) from the joint elements (250) provided between the second plate section (244) and the third plate section (246), wherein the first angle (A1) is equal to (180 / N).

8. A mechanical spring (200) as claimed in any one of claims 1 to 7 wherein each joint element (250) between the first plate section (242) and second plate section (244) of a first pair of adjacent plate sections (240) is aligned with a respective joint element (250) between the third plate section (246) and a fourth plate section (248) of a second pair of adjacent plate sections (240) along a joint element alignment line (252) parallel to longitudinal axis (102); andthe second plate section (244) and third plate section (246) are unconnected along the joint element alignment line (252) such that they are free to move relative to each other along the longitudinal axis (102) in the joint element alignment line (252).

9. A mechanical spring (200) as claimed in any one of claims 1 to 8 wherein the joint elements (250) space adjacent plate sections (240) apart by a first distance (D1), and the plate sections (240) are biased to diverge away from one another up to a second distance (D2) between joint elements (250) between the same adjacent plate sections (240).

10. A mechanical spring (200) as claimed in any one of claims 1 to 8 wherein the joint elements (250) space adjacent plate sections (240) apart by a first distance (D1), and the plate sections (240) are biased to diverge away from one another up to a second distance (D2) at a position halfway between joint elements (250) between the same adjacent plate sections (240).

11. A mechanical spring (200) as claimed in any one of claims 1 to 10 wherein the plate sections (240) have a first thickness (T1) at the joint elements (250) and narrow in thickness to a second thickness (T2) between joint elements (250).

12. A mechanical spring (200) as claimed in any of claims 1 to 11 wherein there are provided at least two joint elements (250) between adjacent plate sections (240).

13. A mechanical spring (200) as claimed in any one of claims 1 to 12 wherein each plate section (240) is circular and centred on the longitudinal axis (102).

14. A mechanical spring (200) as claimed in any one of claims 1 to 13 wherein each plate section (240) defines an aperture (272) centred on the longitudinal axis (102).

15. A mechanical spring (200) as claimed in any one of claims 1 to 14 wherein each plate section is provided as a ring (270) centred on the longitudinal axis (102).

16. A mechanical spring (200) as claimed in any one of claims 13 to 15 wherein when the number of joint elements (250) between adjacent plate sections (240) is two, the joint elements (250) are provided diametrically opposite one another.

17. A mechanical spring (200) as claimed in any one of claims 1 to 16 wherein the joint elements (250) extend radially from a first radial distance (RD1) from the longitudinal axis (102) to a second radial distance (RD2) from the longitudinal axis (102).

18. A mechanical spring (200) as claimed in claim 17 wherein the radial length of the joint elements (250) is at least twice their thickness.

19. A mechanical spring (200) as claimed in claim 16 or claim 17 wherein the radial length of the joint elements (250) is at least twice their height.

20. A mechanical spring (200) as claimed in any one of claims 17 to 19 wherein the joint elements (250) extend from a radially inner edge (262) of the plate section (240) to a radially outer edge (264) of the plate section (240).

21. A mechanical spring (200) as claimed in any one of claims 1 to 20 wherein each plate section (240) extends to a constant radius about its outer circumference.

22. A mechanical spring (200) as claimed in any one of claims 1 to 21 wherein the distance from the radially inner edge (262) to the radially outer edge (264) of each plate section (240) is the same.

23. A mechanical spring (200) as claimed in any of claims 1 to 22 wherein the mechanical spring (200) is integrally formed from a single material.

24. A mechanical spring (200) as claimed in any of claims 1 to 23 wherein the mechanical spring (200) is integrally formed from a material chosen from a list comprising Thermoplastic Elastomer (TPE), Thermoplastic Polyurethane (TPU), Cast Polyurethane (elastomer), Acrylonitrile Butadiene Styrene (ABS), Polycarbonate Polybutylene Terephthalate alloy (PC PBT), Polypropylene (PP), Polyethylene (PE), Thermoplastic Vulcanizate (TPV), Vulcanised Rubber, Steel, or Aluminium.

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