Nested Rolling Element Spring for High Force in Tight Packaging
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Solution Overview
Problem
Existing spring designs for internal combustion engines face challenges in achieving high spring forces within a compact packaging space, particularly in efficiently distributing and managing forces across multiple components to optimize performance and load capacity.
Innovation Solution
A rolling element spring design featuring nested rings and multiple pathways for rolling elements, which includes a unique configuration of conical portions and raceways, allowing for radial expansion and compression of components to generate high spring forces while maintaining a compact structure, and a cage to manage the rolling elements, enabling efficient force distribution and load management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional spring designs are used, then the structure is simple, but the spring force is insufficient and packaging space is not optimized
Solution Approach 1:
The patent implements nesting by placing the second ring inside the first ring and the third ring inside the second ring, creating a compact nested configuration. This allows multiple spring elements to occupy overlapping spatial volumes, significantly increasing the spring force output (up to 65,000 N) while maintaining a compact packaging space that would be impossible with traditional single-ring spring designs.
Solution Approach 2:
The patent transitions from traditional axial compression-only springs to a multi-dimensional design where rolling elements move along inclined raceways at angles (e.g., 30 degrees) relative to the axial direction. This introduces radial and circumferential motion dimensions, enabling the nested rings to generate high spring forces through combined axial and radial deformation modes, thereby increasing force output without proportionally increasing packaging volume.
2Force
If nested rings with multiple rolling elements are used, then high spring forces are achieved, but the device complexity increases
Solution Approach 1:
Each ring in the nested configuration serves multiple functions: the first ring provides outer structural support and engages rolling elements for axial compression; the second ring (nested inside the first) provides additional spring force through its own rolling elements while also serving as a structural carrier for the third ring; the third ring (nested inside the second) contributes further spring force. This multi-functionality allows the system to achieve 65,000 N spring force with a compact component count, as each ring simultaneously provides structural support, rolling element engagement, and spring force generation.
Solution Approach 2:
The patent merges multiple spring functions into a single integrated nested ring assembly. Instead of using separate springs or multiple independent components, the nested rings share common spaces and rolling element pathways, combining their individual spring forces into a unified high-force system. The rolling elements in each ring merge their deformation contributions to produce the total spring force, reducing the number of separate components needed compared to traditional multi-spring assemblies.
3Force
If rolling elements are allowed to move freely, then force distribution is flexible, but control and management of rolling elements becomes difficult
Solution Approach 1:
The cage acts as an intermediary component between the nested rings and the rolling elements. It provides structured guidance and containment for the rolling elements as they move along the inclined raceways during compression and expansion. The cage ensures that rolling elements remain properly positioned and distributed, preventing chaotic movement while still allowing the flexible force distribution characteristic of rolling element springs. This mediator structure makes the system manageable and reliable without sacrificing the force distribution flexibility.
Solution Approach 2:
The system employs dynamic rolling element pathways where the cage and inclined raceways guide rolling elements to move adaptively during compression and expansion. The rolling elements dynamically adjust their positions along the inclined raceways, transitioning between different contact zones as the spring compresses or expands. This dynamic configuration allows flexible force distribution across multiple contact points while the cage maintains orderly control, preventing rolling elements from becoming dislodged or improperly positioned during operation.
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 design effectively generates high spring forces, achieving up to 65,000 N with minimal displacement, enhancing the performance and load capacity of internal combustion engines by optimizing force distribution and maintaining a compact form factor.
Implementation Method 1
The first plurality of rolling elements is arranged between the first ring and the portion of the second ring that is disposed within the first ring. The second plurality of rolling elements is arranged between the first ring and the portion of the third ring that is disposed within the first ring.
Implementation Method 2
compressing the spring: i) moves the first plurality of rolling elements to radially expand the first ring and radially compress the second ring; and, ii) moves the second plurality of rolling elements to radially expand the first ring and radially compress the third ring
Data Source
AI summary
A spring configured to compress, expand, and provide a force is provided that includes a first ring, a second ring, a third ring, a first plurality of rolling elements arranged between the first and second rings, and a second plurality of rolling elements arranged between the first and third rings. When the spring is compressed, the first ring is configured to be elastically deformed in tension in a radially outwardly direction, and the second and third rings are configured to be elastically deformed in compression in a radially inwardly direction.