Compression Spring Core-Shell Assembly for Variable Spring Rate
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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 uniform performance characteristics along their length, limiting variability in performance over the longitudinal length.
Innovation Solution
A compression spring assembly comprising a core and a shell, where the shell is separately provided and assembled with the core to control axial deflection and spring rate, using materials like cured rubber and thermoplastic elastomer, with varying layer configurations and bias angles to achieve different performance characteristics along the length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a greater wall thickness is used in compression spring construction, then structural strength is improved, but curing time increases and production rate decreases
Solution Approach 1:
The compression spring is divided into two separate components: an inner core and an outer shell. The core provides structural strength while the shell provides reinforcement. This segmentation allows each component to be optimized independently - the core can have sufficient thickness for strength without requiring excessive wall thickness, thereby reducing curing time and improving production rate.
Solution Approach 2:
The invention uses a composite construction combining core material and shell material, where the shell acts as a reinforcing layer around the core. This composite structure achieves the required structural strength through the combination of materials and their geometric arrangement, allowing thinner wall sections that cure faster while maintaining overall strength.
2Ease of manufacture
If uniform reinforcing layers are used throughout the compression spring, then manufacturing simplicity is maintained, but performance characteristics cannot be varied along the longitudinal length
Solution Approach 1:
The shell is divided into multiple sections along the longitudinal length, with each section having different reinforcement characteristics (such as different wall thicknesses, material compositions, or braiding patterns). This allows performance characteristics to be varied at different locations along the spring to match specific application requirements, while each section can still be manufactured using standardized processes.
Solution Approach 2:
The shell is segmented into multiple discrete sections that can be manufactured separately and then assembled around the core. This segmentation enables different performance characteristics in different sections while maintaining manufacturing simplicity through modular production and assembly processes.
Data Source
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.