Leaf Spring Damping Frame Assembly for Uniform Vibration Actuators
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Solution Overview
Problem
Conventional vibration actuators face challenges with high production costs and complex assembly processes due to precise alignment and adhesion requirements of damping members with leaf springs, leading to uneven vibration characteristics and durability issues.
Innovation Solution
The vibration actuator design integrates a frame and leaf spring using overmolding, with a damping portion protruding inward from the casing and spiral arms connecting the inner and outer circumferential portions, facilitating accurate positioning and strong adhesion of the damping member, reducing assembly complexity and improving vibration characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the damping member is precisely formed along the shape of the leaf spring arm and accurately aligned, then the vibration characteristic is improved, but the production cost increases and the assembly process becomes complex
Solution Approach 1:
The damping member is integrated with the frame through overmolding, merging two previously separate components into a single unified structure. This eliminates the need for separate alignment and adhesion processes, simplifying assembly while maintaining vibration performance.
Solution Approach 2:
The damping member is pre-formed with a shape that matches the leaf spring arm configuration, and the overmolding process pre-positions it accurately on the frame. This preliminary shaping and positioning eliminates the need for complex post-assembly alignment operations.
2Reliability
If the damping member is fixed on the inner circumference of the leaf spring, then the vibration characteristic is controlled, but the amplitude stress concentrates on the damping member leading to deterioration of durability
Solution Approach 1:
The damping member and frame are merged into a single integrated component through overmolding, creating a unified structure that distributes stress more evenly. This prevents stress concentration at the damping member-leaf spring interface, improving durability while maintaining vibration control.
3Ease of manufacture
If there is variation in the fixing position of the casing and leaf spring or leaf spring and damping member, then the assembly is more flexible, but the positional relationship becomes non-uniform leading to non-uniform vibration characteristic
Solution Approach 1:
By integrating the damping member with the frame through overmolding, the patent creates a single rigid structure that eliminates relative movement and positional variations between components. This ensures uniform vibration characteristics while maintaining assembly flexibility through the integrated design.
Solution Approach 2:
The overmolding process pre-positions the damping member at the exact required location on the frame, eliminating positional variations before assembly. This preliminary positioning ensures uniform vibration characteristics without requiring complex assembly fixtures or alignment procedures.
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 configuration simplifies assembly, enhances vibration performance, and improves durability by ensuring uniform damping and reduced risk of damping member damage, resulting in a more efficient and reliable vibration actuator.
Implementation Method 1
a coil fixed to the casing is arranged around the mover, and power is conducted through the coil to reciprocate the mover inside the casing
Implementation Method 2
disc-shaped leaf spring with multiple arms is used to reciprocally support the mover relative to the casing
Implementation Method 3
a damping member to control the vibration characteristic is provided in the leaf spring
Data Source
AI summary
Assembling of the leaf spring and the damping member is facilitated and a vibration actuator with excellent vibration characteristic is provided. The vibration actuator mainly includes a cylindrical casing, a coil provided inside the casing, a mover vibrating along the vibration axis of the casing, a leaf spring in which an inner circumferential portion thereof is fixed to the mover, and a frame fixing the leaf spring to the casing. The frame includes a fixing portion provided in an outer circumferential portion of the leaf spring and a damping portion provided in a vibrating portion of the leaf spring.