Superimposed Opposing Wave Spring Structure for Verticality and Stroke
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Solution Overview
Problem
Traditional opposing wave springs face challenges in maintaining good verticality and elastic performance simultaneously while ensuring greater stiffness and a higher available stroke.
Innovation Solution
A superimposed opposing wave spring design featuring overlapping wave shapes in each layer and connection spring parts that interconnect adjacent units, allowing for improved verticality and elastic performance, with the ability to adjust stiffness by varying the number of layers and using a flat metal wire for integral formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If waveforms of respective layers are arranged to overlap each other (superimposed-layer structure), then verticality is improved, but available stroke becomes short and elastic performance deteriorates
Solution Approach 1:
The wave spring is divided into multiple superimposed-layer wave spring units, where each unit contains layers with overlapping waveforms that provide good verticality. Connection spring parts connect these units, allowing each unit to function independently with sufficient stroke capability. This segmentation resolves the contradiction by localizing the overlapping structure to specific units rather than requiring all layers to overlap simultaneously.
Solution Approach 2:
Connection spring parts serve as intermediaries between superimposed-layer wave spring units. These connection parts enable the units to work together as a unified structure while preserving the stroke capability of individual units. The connection spring parts transfer forces and movements between units, allowing the overall structure to achieve both good verticality (from overlapping layers in each unit) and sufficient available stroke (through the articulated connection between units).
2Ease of manufacture
If traditional opposing wave spring structure is used, then manufacturing is simple, but verticality is poor and elastic performance is insufficient
Solution Approach 1:
The wave spring structure is segmented into multiple superimposed-layer wave spring units connected by connection spring parts. This segmentation allows each unit to be formed with good verticality through overlapping waveforms, while the entire structure remains manufacturable using conventional winding processes. The modular unit structure simplifies the manufacturing complexity by breaking down the overall structure into repeatable units.
Solution Approach 2:
Multiple layers within each superimposed-layer wave spring unit are nested with overlapping waveforms, creating a compact structure with improved verticality. The connection spring parts nest between these layered units, connecting them in a space-efficient manner. This nested arrangement maintains manufacturing simplicity while achieving superior verticality compared to traditional opposing wave springs.
3Strength
If number of layers is increased to improve stiffness, then elastic performance may deteriorate, but if number of layers is decreased, then stiffness is insufficient
Solution Approach 1:
The wave spring is segmented into multiple units, each containing a specific number of superimposed layers. This segmentation allows optimization of the layer count in each unit to balance stiffness and elastic performance. Connection spring parts link these units, enabling the overall structure to achieve high stiffness through the combined effect of multiple units while preserving elastic performance through the flexible connections between units.
Solution Approach 2:
The connection spring parts introduce dynamic flexibility between the superimposed-layer wave spring units. This dynamic connection allows the structure to adapt its stiffness characteristics based on the loading conditions and relative movements between units. The system can exhibit higher effective stiffness when units work together while maintaining elastic performance through the flexible, movable connections between units.
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 enhances elastic performance and available stroke while maintaining better verticality and adjustable stiffness, enabling production of wave springs with variable characteristics to meet diverse needs.
Implementation Method 1
each layer in each superimposed-layer wave spring unit is formed by spirally bending around an axis into a wave shape
Implementation Method 2
the two adjacent superimposed-layer wave spring units respectively have a first wave trough and a second wave crest that are abutting each other with opposing apexes
Data Source
AI summary
The present application provides a superimposed opposing wave spring that has a plurality of superimposed-layer wave spring units, wherein each layer in each superimposed-layer wave spring unit is formed by spirally bending around an axis into a wave shape, and waveforms of the respective layers in each superimposed-layer wave spring unit are arranged to overlap each other. At least one connection spring part, which connects two adjacent superimposed-layer wave spring units that are stacked one above the other, so that the two adjacent superimposed-layer wave spring units respectively have a first wave trough and a second wave crest that are abutting each other with opposing apexes, and respectively have a first wave crest and a second wave trough that are arranged across from each other in an upper position and a lower position.