Plastic Spring Geometry for Better Compression Force Development
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Solution Overview
Problem
Existing plastic springs do not effectively optimize force development and plastic deformation, particularly in compression applications.
Innovation Solution
The design features pairs of oppositely curved intermediate rings with increased width along the longitudinal axis, widened run-in regions, and specific spring leg configurations to enhance force introduction and deformation characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If spring legs extend over more than 90 degrees in the circumferential direction with widened run-in regions, then force development is optimized, but manufacturing complexity increases
Solution Approach 1:
The spring legs are designed with curved geometries extending over more than 90 degrees in the circumferential direction, and the run-in regions are widened with curved transition surfaces. This curvature optimization improves force distribution and development characteristics while maintaining integral manufacturability through injection molding processes.
Solution Approach 2:
The run-in regions of the spring legs are locally widened compared to the main body of the spring legs. This local quality enhancement concentrates structural complexity only where needed for optimal force introduction into the spring rings, while the remaining portions maintain simpler geometries for easier manufacturing.
2Stability of the object's composition
If intermediate rings are widened by 10 percent or more along the longitudinal axis, then plastic deformation is optimized, but material consumption increases
Solution Approach 1:
The intermediate rings are widened by 10 percent or more along the longitudinal axis compared to the spring rings, creating localized zones that enhance plastic deformation capabilities. This selective widening is applied only where needed for optimal spring behavior, minimizing overall material consumption while achieving the desired deformation characteristics.
3Force
If spring legs have asymmetric width distribution with widened run-in regions, then force introduction is improved, but manufacturing precision requirements increase
Solution Approach 1:
The spring legs feature asymmetric width distribution with widened run-in regions that transition smoothly into the main body. These geometric parameter changes are optimized to improve force introduction characteristics while maintaining manufacturability through standard injection molding processes, avoiding overly tight tolerances.
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 achieves favorable force development and plastic deformation, ensuring optimal spring behavior and resilience.
Implementation Method 1
the spring rings are connected to one another compressibly by means of spring legs
Data Source
AI summary
A plastic spring includes a lower spring ring and an upper spring ring, which are arranged essentially coaxially to one another, wherein a plane, which is in each case spanned by the spring rings, extends essentially perpendicular to a longitudinal axis of the plastic spring, and wherein, in addition, the spring rings are connected to one another compressibly by spring legs, which extend over more than 90 degrees in the circumferential direction, wherein the spring legs run into the lower and/or upper spring ring in a transition portion, wherein a spring leg further has a central longitudinal axis, which follows the curved progression of the spring leg.