Flexible Spring Member Seamless Winding Process
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Solution Overview
Problem
Conventional flexible spring members for gas spring assemblies have overlapping seams that lead to uneven thickness, altered flexibility, and torsional imbalance, posing challenges in manufacturing and performance.
Innovation Solution
A seamless manufacturing process for flexible spring members using a direct winding method without overlapping edges, employing a creel assembly, tensioning system, and cord winding comb head assembly to apply reinforcement cords in a non-overlapping, helically wrapped configuration, ensuring uniform tension and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional overlapping seam construction is used, then manufacturing process is simpler, but thickness uniformity and flexibility performance deteriorate
Solution Approach 1:
The reinforcing fabric is divided into multiple plies (first ply, second ply, third ply) with different cord orientations. Each ply is separately constructed and then assembled, allowing control over thickness at seams while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
Different regions of the spring member have different constructions: the body portion uses multiple plies with overlapping seams for strength, while the end portions use single-ply construction without seams for uniform thickness. This local differentiation resolves the contradiction between ease of manufacture and thickness uniformity.
2Ease of manufacture
If conventional overlapping seam construction is used, then manufacturing process is simpler, but torsional balance and flexibility performance deteriorate
Solution Approach 1:
The spring member is segmented into distinct functional zones: a body portion with multiple plies for torsional stability and end portions with single-ply construction for uniform flexibility. This segmentation allows each region to be optimized independently for its specific function.
Solution Approach 2:
The spring member employs asymmetric construction where the number of plies varies along the longitudinal axis. The end portions have fewer plies than the body portion, creating intentional asymmetry that compensates for seam effects and restores torsional balance while maintaining manufacturing simplicity.
3Strength
If multiple plies of reinforcing fabric are used, then strength is improved, but number of seams and manufacturing complexity increase
Solution Approach 1:
The reinforcing fabric is divided into multiple plies with different cord orientations (first ply at first angle, second ply at second angle, third ply at third angle). Each ply contributes to strength in different directions, achieving comprehensive strength enhancement without requiring excessive seams.
Solution Approach 2:
Multiple plies are merged into a single integrated construction where the body portion combines multiple overlapping seams for maximum strength, while the end portions use single-ply construction. This merging strategy achieves high strength where needed without unnecessarily increasing overall manufacturing complexity.
Data Source
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AI summary
Systems include a creel assembly (102) supporting a plurality of spools (104) containing at least one cord (106) having an indeterminate length such that a plurality of cords are supported on the creel assembly. A tensioner assembly (114) operative to tension approximately equal predetermined lengths of the plurality of cords received from the creel assembly. A building mandrel (128) supported for rotation and translation. A head assembly (116) supported in fixed relation to the building mandrel. The head assembly is positioned co-axially such that the building mandrel can pass through an opening in the head assembly during translation. Methods of manufacture are included, as are flexible spring members and gas spring assemblies.