Flat In-Plane Flexure Spring for Assembly-Free Micro Mechanisms
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Solution Overview
Problem
Conventional coil springs are difficult to assemble in micro-mechanical instruments, leading to issues with size, assembly complexity, and unwanted wear and noise due to rotation during deflection, which are not suitable for modern demands in smaller, lightweight, and compact mechanical components.
Innovation Solution
A scalable flat in-plane-motion mechanical spring device formed as a single piece, comprising a frame and shuttle with attached flexures, allowing for easy manufacturing through various CNC and 3D printing techniques, and providing a compact, assembly-free, and precise mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coil springs are used in micro-mechanical instruments, then they can provide mechanical energy storage and actuation, but they are difficult to assemble and increase device complexity
Solution Approach 1:
The patent combines the frame and flexures into a single integrated component that functions as both the structural support and the energy storage element. The flexures are formed as an integral part of the frame, eliminating the need for separate coil springs and reducing assembly steps while maintaining mechanical energy storage capability
Solution Approach 2:
The frame is divided into multiple flexures that can independently deflect and store energy. Each flexure acts as a separate functional unit within the integrated structure, allowing for distributed energy storage and reduced complexity compared to a single coil spring
2Volume of moving object
If coil springs are used to reduce size, then they can provide compact energy storage, but they rotate during deflection causing wear and noise
Solution Approach 1:
Instead of using a traditional coil spring that rotates during deflection, the patent inverts the approach by using flat flexures that deflect in-plane without rotation. The energy storage mechanism is reversed from torsional coil deformation to bending flexure deformation, eliminating the harmful rotational wear and noise
Solution Approach 2:
The patent uses thin flexure elements that bend and deflect to store energy. These flexible flat elements replace the rigid rotating coil structure, providing compact energy storage without the rotational harmful effects through controlled elastic deformation of thin structural elements
3Ease of operation
If traditional multi-component spring assemblies are used, then they can provide mechanical functionality, but they increase manufacturing complexity and reduce productivity
Solution Approach 1:
The frame and flexures are merged into a single monolithic component that can be manufactured in one process. This integration eliminates multiple assembly operations and increases manufacturing productivity while preserving all necessary mechanical functions through the integrated structure's design
Solution Approach 2:
The integrated frame structure serves multiple functions simultaneously: it provides structural support, acts as the mounting platform, and contains the energy-storing flexures. This multi-functionality in a single component reduces manufacturing complexity and increases productivity compared to separate specialized parts
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
The solution enables the creation of compact, lightweight mechanical components with reduced friction and surface forces, suitable for micro-scale applications, such as energy storage and actuation in diverse devices, while maintaining scalability and precision.
Implementation Method 1
a scalable flat in-plane-motion mechanical spring device
Data Source
AI summary
A scalable flat in-plane-motion mechanical spring device. The device sincludes a frame with one or more flexures attached to the frame on a first end of the one or more flexures. The device further includes a shuttle with one or more of the one or more flexures attached to the shuttle on a second end of the one or more flexures. The frame, the shuttle, and the one or more flexures may be formed as a single piece.