Single-Wire Nested Coil Spring for High Force Density
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Solution Overview
Problem
Conventional springs are limited by their ability to store a relatively small amount of mechanical force in relation to their size, often requiring multiple springs for desired strength, and may not fit into specific applications due to size constraints.
Innovation Solution
A coil spring design featuring multiple external coils defining an inner lumen, with a first internal coil partially extending into the lumen, made from a single continuous spring wire, allowing for contact between adjacent external coils and internal coil placement when at rest, and optionally configured as a tension or compression spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional springs are used to store mechanical force, then the spring can provide basic elastic function, but the mechanical force storage capacity is limited relative to the spring size
Solution Approach 1:
The patent applies nesting by placing an internal coil inside the external coil, with the internal coil extending into the inner lumen of the external coil. This nested configuration allows both coils to occupy overlapping spatial volumes, effectively doubling the elastic elements within a single spring envelope, thereby increasing mechanical force storage capacity without proportionally increasing overall spring size
Solution Approach 2:
The patent utilizes the third dimension by having the internal coil extend axially into the inner lumen of the external coil rather than placing it side-by-side. This vertical stacking in the axial dimension allows maximum utilization of the available internal space, enabling higher force storage density within the same external dimensions
2Strength
If multiple springs are used to achieve desired strength, then the mechanical force capacity increases, but the space required increases
Solution Approach 1:
The patent merges two separate spring elements (external coil and internal coil) into a single integrated spring structure. Both coils are formed from continuous wire and are part of the same spring assembly, allowing them to occupy overlapping spatial volumes rather than requiring separate installation spaces. This merging enables multiple elastic elements to function within the footprint of a single spring
3Strength
If a larger spring is used to get desired strength, then the mechanical force capacity increases, but the spring may not fit into the application space
Solution Approach 1:
The nested configuration of internal and external coils allows the spring to maintain compact external dimensions while providing enhanced force capacity. The internal coil is contained within the inner lumen of the external coil, ensuring the overall spring envelope remains small enough to fit into constrained application spaces while delivering the strength of multiple springs
4Strength
If conventional spring design is used, then the structure is simple, but the mechanical force storage per unit volume is low
Solution Approach 1:
While the nested structure does increase complexity compared to a single coil, the patent maintains relative simplicity by using a consistent single-wire construction method for both coils, with the internal coil simply extending into the available internal space. The manufacturing process remains fundamentally the same, and the structural complexity is justified by the significant improvement in force storage density
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 advanced spring design enhances mechanical force storage capacity while maintaining a compact size, enabling effective use in applications like orthodontic braces and various machinery without the need for multiple springs, and maintaining elasticity over extended periods.
Implementation Method 1
a spring comprises an elastic material that is configured to store mechanical energy when the spring is stretched, compressed, twisted, deflected, or otherwise caused to change its configuration
Data Source
AI summary
An advanced (or supercoil) spring is disclosed herein. While the advanced spring can include any suitable feature, in some cases, it includes a coil spring having multiple external coils that define a portion of an inner lumen of the coil spring. In some such case, the coil spring further includes a first internal coil that extends at least partially into the inner lumen of the coil spring. In some cases, the external coils and the first internal coil are each made of, and comprise part of, one single continuous spring wire. In some cases, the coil spring includes a tension spring such that surfaces of adjacent external coils contact each other, and such that the first internal coil is disposed within a portion of the inner lumen defined by the adjacent external coils, when the coil spring is at rest. Additional implementations are discussed herein.