Compression Spring Core-Shell Assembly to Reduce Curing Time
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Solution Overview
Problem
Conventional compression springs face challenges such as increased curing times due to thicker wall thickness, which reduces production rates and increases costs, and are poorly suited for varying performance characteristics along their longitudinal length.
Innovation Solution
A compression spring assembly comprising a separate compression spring core and shell, where the shell restricts radially-outward expansion of the core, allowing for controlled axial deflection and spring rate, and featuring varying reinforcing layers and core-displacement voids to achieve desired performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a greater wall thickness is used in compression spring construction, then the structural strength is improved, but the curing time increases and production rate decreases
Solution Approach 1:
The compression spring is divided into two separate components: a core and a shell. The core provides the primary structural strength, while the shell adds reinforcement only where needed. This segmentation allows each component to be manufactured with optimized wall thickness, reducing overall curing time while maintaining required strength.
Solution Approach 2:
The shell is designed with varying thickness along the longitudinal length of the spring, providing localized reinforcement where performance characteristics require it. This allows different sections of the spring to have different structural properties without requiring uniform thick walls throughout, thereby reducing overall curing time.
2Ease of manufacture
If a monolithic structure with uniform reinforcing layers is used, then the manufacturing process is simplified, but the ability to achieve variable performance characteristics along the longitudinal length is lost
Solution Approach 1:
By separating the spring into core and shell components, each can be manufactured using simplified processes. The shell is then wrapped around the core, allowing different sections of the shell to have different reinforcement characteristics. This segmentation enables variable performance along the longitudinal length while keeping individual manufacturing steps relatively simple.
Solution Approach 2:
The shell can be manufactured with locally varied properties, such as different thicknesses, reinforcement densities, or material compositions at different longitudinal positions. This allows the spring to achieve variable performance characteristics (softer or stiffer sections) without requiring complex monolithic manufacturing processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances production efficiency by reducing curing times and enables variable performance characteristics along the spring length, improving manufacturing flexibility and performance.
Implementation Method 1
the compression spring core will tend to flow or deflect in at least a radially outward direction under axially-compressive load conditions
Data Source
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AI summary
A compression spring assembly can include a compression spring core and a compression spring shell that can be assembled onto the compression spring core. The compression spring core can include a core body with an outer core wall. The compression spring shell can include a shell body having an inner shell wall. The compression spring shell can be supported on the compression spring core such that the inner shell wall extends along at least a portion of the outer core wall. A method of manufacturing a compression spring assembly is also included.