Lamellar Rotational Flexure Pivot Single-Step Bonding
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Solution Overview
Problem
Existing flexure pivots face challenges such as high manufacturing costs, limited material options, size constraints, and complex assembly processes due to the need for precise bonding and machining, which restrict their scalability and applicability.
Innovation Solution
A lamellar rotational flexure pivot design that stacks flat spring and spacer layers with a divider layer, allowing for simplified assembly and bonding in a single step, enabling dimensional scalability and increased material options through automation and efficient manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bonding methods (braising or welding) are used to join springs to quads, then strong structural joints are achieved, but the manufacturing process becomes complex and expensive requiring two separate bonding steps
Solution Approach 1:
The patent combines the core assembly and final assembly bonding operations into a single bonding step. The mounting features are pre-formed on the springs before core assembly, allowing the springs to be directly bonded to the quads in one operation rather than requiring separate bonding steps for core assembly and final assembly.
Solution Approach 2:
The mounting features (protrusions and recesses) are pre-formed on the springs before the bonding process. This preliminary formation of mounting features allows the bonding operation to simultaneously accomplish both core assembly and final assembly, eliminating the need for a second bonding step.
2Manufacturing precision
If precision rolling is used to manufacture springs to required thickness, then manufacturing precision is improved, but material options are limited and batch production is required
Solution Approach 1:
The patent changes the manufacturing approach from precision rolling to alternative methods such as precision cutting or forming processes. This parameter change in the manufacturing method allows the use of a broader range of materials including those that cannot be precision rolled, while still achieving the required thickness precision through these alternative processes.
3Reliability
If complex machining is performed to create undercuts on the core, then proper pivot function is achieved, but manufacturing time and cost increase
Solution Approach 1:
The mounting features are pre-formed on the springs before assembly into the core. This preliminary action eliminates the need for complex post-assembly machining operations to create undercuts, as the mounting features are already in place to guide proper alignment and function.
4Strength
If multiple bonding steps are required for core assembly and final assembly, then structural integrity is maintained, but manufacturing cost and time increase
Solution Approach 1:
The patent merges the core assembly bonding and final assembly bonding into a single bonding operation. The pre-formed mounting features on the springs enable this consolidation, allowing both assembly stages to be completed in one bonding step while maintaining the required structural integrity.
Solution Approach 2:
By pre-forming the mounting features before assembly, the patent enables a single bonding step to accomplish what traditionally required two separate bonding operations, thereby reducing manufacturing cycle time while preserving structural integrity.
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 manufacturability, reduces costs, and improves durability by distributing loads evenly, allowing for a wider range of applications and sizes, including nano-scale applications, while simplifying the assembly and integration of mounting features.
Implementation Method 1
a first spring layer, a second spring layer... wherein the first spring layer may be rotationally offset from the second spring layer
Data Source
AI summary
A lamellar rotational flexure pivot may include a first pivot end, and second pivot end, and a divider layer positioned therebetween to allow first and second pivot ends to pivot relative to one another. The first and second pivot ends may include a plurality of spring layers and spacer layers that are stacked in alternating fashion to form the lamellar rotational flexure pivot.