Self-Contained Adjustable Spring Plunger Bumper with High Initial Load

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Solution Overview

Problem

Existing spring plunger bumpers face issues with high initial load and low final load configurations, leading to plunger sticking and excessive stress at the ball ramp interface, which can result in actuation failure and increased wear, and are often non-self-contained and non-adjustable, making them unsuitable for certain applications.

Innovation Solution

A self-contained spring plunger unit with a distinct return spring and high load spring configuration, featuring a ramp sleeve and displacement ball system that provides a high initial load while maintaining a low final load, allowing for adjustable positioning and reduced wear through optimized spring rates and angles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a single spring is used for both plunger return and high initial load, then the bumper achieves high initial load in compact size, but the plunger may get stuck and not reset due to insufficient return force

Engineering Contradiction:

Improveinitial loadVSAvoidplunger reset reliability

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The patent divides the single spring function into two separate springs: a first spring dedicated to providing high initial load through the ball ramp mechanism, and a second spring dedicated to providing return force to overcome friction and reset the plunger. This segmentation allows each spring to be optimized for its specific function, ensuring both high initial load and reliable reset operation.

Inventive Principle:

Principle #1Segmentation

2Force

If the inclined angles are increased to multiply spring force for high initial load, then the bumper achieves higher force multiplication, but excessive stress occurs at the ball ramp interface causing wear and actuation failure

Engineering Contradiction:

Improveinitial loadVSAvoidball ramp interface strength

Core Design Contradiction:

ForceVSStrength

Solution Approach 1:

The patent separates the force multiplication function (first spring through ball ramp) from the return function (second spring), allowing the first spring to be optimized for force multiplication with appropriate inclined angles while the second spring handles the return load. This prevents excessive stress concentration at the ball ramp interface that would occur if a single spring tried to provide both functions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent optimizes the inclined angles of the ball ramp and spring rates to achieve the desired force multiplication while maintaining acceptable stress levels. By carefully selecting these parameters and separating the spring functions, the system achieves high initial load without excessive wear at the ball ramp interface.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If conventional leaf spring bumpers are used for adjustable positioning, then the bumper achieves adjustability, but the configuration is hard to configure and has limited durability

Engineering Contradiction:

Improveposition adjustabilityVSAvoidbumper durability

Core Design Contradiction:

Adaptability or versatilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces the conventional leaf spring mechanism with a spring-plunger-ball ramp system. This substitution provides adjustability through the plunger position while using the spring-ramp-ball mechanism to provide durable, repeatable mechanical action with proper force profiles, overcoming the limitations of leaf spring configurations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution achieves a high initial load with a low final load, reducing wear and ensuring reliable actuation while maintaining a compact, self-contained design, suitable for applications requiring precise force profiles and durability.

Implementation Method 1

a first spring providing expansion force between a first spring surface of the body and a second spring surface of the plunger

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 2

a second spring providing expansion force between a third spring surface of the plunger and a fourth spring surface of the body

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS10073487B2Systems and methods for self-contained adjustable spring plunger bumper with high initial load and low final load

Publication Date: 2018.09.11 PRINCE IND LLC

AI summary

A system and method is provided for an adjustable spring plunger bumper with high initial load and low final load. The spring plunger bumper includes an exterior body surrounding a plunger. The plunger has a plunger indent into which a displacement ball is induced by a ramp sleeve biased by a ramp sleeve spring. As the plunger is displaced relative to the exterior body, the displacement ball contacts a lower displacement ball inclined surface, which provides a high initial load resisting the displacement of the plunger. However, as the displacement of the plunger continues, the displacement ball comes into contact with a smooth lower displacement ball indent surface which provides a lower load. A return spring is positioned between the plunger and the exterior body to return them to their initial position relative to each other when the displacement of the plunger is removed.