Continuous Nested Crest-to-Crest Wave Spring for Load and Deflection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wave springs face challenges in supporting heavier loads while achieving higher deflections, and they are prone to manufacturing difficulties and operational misalignment issues, especially in interlaced crest-to-crest wave springs.
Innovation Solution
A nested crest-to-crest wave spring is formed from a single, continuous piece of flat wire by coiling a nested wave spring and shifting the coil direction to create subsequent nested springs without breaking the wire or using fastening methods, allowing for multiple stacks in a crest-to-crest configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If interlaced crest-to-crest wave springs are used to support heavier loads and achieve higher deflections, then load capacity and deflection are improved, but manufacturing complexity increases and operational misalignment occurs
Solution Approach 1:
The patent merges multiple crest-to-crest wave spring stacks into a single integrated structure formed from one continuous piece of flat wire. Instead of manufacturing separate leaves and joining them (as in interlaced springs), the invention combines the functions of multiple stacks into a unitary component that is formed in a single manufacturing process, eliminating alignment and fastening complexities.
Solution Approach 2:
The patent segments the continuous flat wire into multiple nested stacks during the forming process. The wire is coiled and folded to create distinct stack sections (first stack, second stack, etc.) that are interconnected through turns, allowing each stack to function independently while maintaining structural integration. This segmentation enables complex geometry without requiring post-assembly operations.
2Force
If interlaced crest-to-crest wave springs are used to support heavier loads and achieve higher deflections, then load capacity and deflection are improved, but operational reliability deteriorates due to misalignment
Solution Approach 1:
By merging multiple stacks into a single continuous wire structure, the invention eliminates the relative movement and misalignment that occurs between separate leaves in interlaced springs. The unitary construction ensures that all stacks move together as one integrated component during compression and expansion cycles, maintaining operational reliability under repeated loading.
Solution Approach 2:
Instead of joining multiple separate components to achieve integration (as in interlaced springs), the invention inverts the approach by starting with a single continuous component and shaping it to create multiple functional stacks. This reversal of the assembly logic inherently prevents misalignment issues that plague traditional interlaced designs.
3Force
If nested wave springs are used to support heavier loads, then load capacity is improved, but deflection capability is reduced
Solution Approach 1:
The patent applies nesting by placing multiple stacks of crest-to-crest wave springs inside one another in a hierarchical arrangement. The first stack, second stack, and additional stacks are nested concentrically, with each stack providing additional deflection capability while the combined structure supports heavier loads. The nesting allows compact arrangement of multiple functional elements.
Solution Approach 2:
The invention transitions from a single-plane wave structure to a multi-dimensional nested arrangement. By stacking multiple crest-to-crest stacks in concentric dimensions and connecting them through turns, the patent creates a three-dimensional structure that simultaneously achieves high load capacity (through multiple stacks) and high deflection (through the crest-to-crest geometry of each stack).
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 load-carrying capacity and deflection capabilities compared to traditional nested wave springs, while eliminating manufacturing complexities and operational misalignment issues associated with interlaced designs.
Implementation Method 1
single turn waves are patterned into single turn waves that change their shape (i.e., deflect) under loads
Data Source
AI summary
A nested crest-to-crest wave spring formed from a single, continuous piece of flat wire by coiling a nested wave spring, then shifting the direction of the coil to form a subsequent nested spring that stacks upon the original nested spring without breaking the wire or using any method to fasten the nested springs together. This process can be repeated to stack multiple nested springs together in a crest-to-crest configuration. This process creates a crest-to-crest wave spring that can withstand increased loading over a crest-to-crest wave spring while providing more deflection than a nested wave spring. These changes in wave direction and the number of stacks can be made to any number to achieve the desired load and/or deflection.