Flat-Ended Wave Spring Mitigates Mating Surface Damage
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Solution Overview
Problem
Existing flat wire, gap-type, single turn wave springs with sharp corners at the gap can damage mating parts of an assembly, and this damage worsens as the springs become taller, leading to scratching, debris creation, and potential failure.
Innovation Solution
The wave spring design features flattened portions adjacent to the gap, allowing these flat ends to glide smoothly along the mating surface, eliminating sharp edges that cause damage, and maintaining contact without digging in, regardless of compression or height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the spring height is increased, then the spring's load-bearing capacity is improved, but the sharp corners at the gap cause more damage to mating parts
Solution Approach 1:
The patent applies local quality by modifying only the end portions of the wave spring where they contact mating parts. The flats are created specifically at the ends adjacent to the gap, while the rest of the spring body maintains its original wave structure. This localized modification eliminates sharp corners at the contact points without altering the overall spring geometry or load-bearing capacity.
Solution Approach 2:
The flattening of the end portions is performed as a preliminary action during manufacturing, before the spring is installed. This pre-processing step ensures that the harmful sharp corners are eliminated in advance, preventing damage to mating parts from the outset rather than requiring corrective actions after installation.
2Length of moving object
If the spring height is increased, then the spring's deflection capability is improved, but the sharp edges scratch and dig into the mating surface
Solution Approach 1:
The patent applies local quality by modifying only the end portions of the wave spring where they contact mating parts. The flats are created specifically at the ends adjacent to the gap, while the rest of the spring body maintains its original wave structure. This localized modification eliminates sharp corners at the contact points without altering the overall spring geometry or load-bearing capacity.
Solution Approach 2:
The patent converts the potentially harmful sharp corners into beneficial flat surfaces. By flattening the end portions, the sharp edges that would normally cause scratching are transformed into smooth contact surfaces that glide along the mating surface, converting a harmful geometric feature into a beneficial one.
3Force
If the spring is compressed, then the spring's load-bearing function is activated, but the sharp corners worsen and cause increased damage
Solution Approach 1:
The patent applies local quality by modifying only the end portions of the wave spring where they contact mating parts. The flats are created specifically at the ends adjacent to the gap, while the rest of the spring body maintains its original wave structure. This localized modification eliminates sharp corners at the contact points without altering the overall spring geometry or load-bearing capacity.
Solution Approach 2:
The patent applies dynamics by ensuring that the flattened end portions can adapt their orientation during compression. The flats are positioned radially to the central axis, allowing them to maintain optimal contact with the mating surface as the spring deflects, ensuring smooth gliding motion throughout the compression cycle.
Data Source
Figure 1~1A
Figure 2~2A
Figure 3
AI summary
A flat wire, gap-type, single turn wave spring made using a coiling manufacturing process wherein the portions of the spring adjacent the gap are made flat The flat portions are configured to abut a mating assembly. Flat wire and round wire wave springs and their methods of manufacture are known in the art. Presently known flat wire, gap-type, single turn wave springs have sharp comers in the cut ends at the gap that can damage the mating parts of an assembly. As these prior art wave springs are made taller, with increased height, the problem of damage is made worse.