Variable Force Spring Tape Laser Cutting Process

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Solution Overview

Problem

Existing flat tapered tape spring motors are not efficiently manufacturable using commercially available equipment, and there is a need for a B-type motor that can be effectively used in product display tethering applications like the PULLBOX product, where efficient manufacturing and quiet operation are required.

Innovation Solution

A novel process using laser cutting to create a flat tapered spring tape with complementary shapes on opposite sides, allowing for efficient production and assembly into a B-type spring motor, where the tape is cut by a laser beam to form a continuous free edge in a saw tooth configuration, and then split into identical strips for pre-stressing and coiling, ensuring minimal material waste and quiet operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing methods are used for flat tapered tape spring motors, then the manufacturing process is simple, but the manufacturing efficiency is low and material waste is high

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical cutting methods with laser technology to manufacture flat tapered tape springs. The laser beam precisely cuts and shapes the tape material, enabling complex tapered geometries to be produced efficiently without traditional mechanical tooling, thereby improving manufacturing efficiency while reducing material waste through precise control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes laser parameters (power, speed, focal position) to control the cutting and shaping process of the tape material. By adjusting these parameters, the manufacturing process can efficiently produce various tapered configurations with minimal material waste, resolving the contradiction between manufacturing efficiency and process complexity.

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If conventional tape cutting methods are used, then the process is straightforward, but material waste is significant

Engineering Contradiction:

Improvematerial wasteVSAvoidtape shape precision

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent employs laser cutting technology to precisely remove material from the tape stock. The laser beam can be precisely controlled to follow the exact tapered profile required, minimizing excess material removal and significantly reducing material waste compared to conventional mechanical cutting methods while achieving high manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser cutting process uses digital programming to precisely replicate the desired tapered tape profile. This allows for exact reproduction of the required geometry with minimal material waste, as the laser path is programmed to match the precise contours needed without requiring physical templates or fixtures.

Inventive Principle:

Principle #26Copying

3Object-affected harmful factors

If standard tape configurations are used, then manufacturing is easier, but noise levels increase in operation

Engineering Contradiction:

Improveoperational noiseVSAvoidmanufacturing simplicity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The laser manufacturing process enables creation of optimized tape geometries that reduce operational noise. The precise control of the laser cutting allows for tapered edges and surface finishes that minimize vibration and noise during spring operation, achieving low-noise performance without significantly complicating the manufacturing process.

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 process enables the efficient manufacture of flat tapered tape spring motors that can be used in applications requiring low noise, such as product display tethering, while minimizing material waste and ensuring proper centering and engagement with spool flanges, thus addressing the inefficiencies of previous manufacturing methods.

Implementation Method 1

A novel process using laser cutting to create a flat tapered spring tape with complementary shapes on opposite sides

Methodology Applied

Scientific EffectLaser cutting: Laser Ablation

Implementation Method 2

a length of pre-stressed tape, or ribbon, is wrapped around first and second spools rotatable about spaced parallel axes

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9038272B1Variable force spring tapes and method of manufacture

Publication Date: 2015.05.26 VULCAN SPRING & MANUFACTURING CO

AI summary

A spring tape suitable for use in spring motor applications where reactive torque varies with rotational deflection. An elongate elastic element is advanced lengthwise and is laser cut into longitudinally complementary shapes which are separated and subsequently pre-stressed into rolls which are cut to length for assembly into a spring motor.