Wave Washer Flat Protrusions Reduce Wear and Noise
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Solution Overview
Problem
Conventional wave washers are prone to wear when in contact with parts, leading to deterioration of their springiness and increased noise in variable-flow-rate valves due to collisions.
Innovation Solution
A wave washer with an annular body formed in a wave shape and protruding pieces having flat surfaces perpendicular to the axis, which increases the contact area and reduces surface pressure, thereby minimizing wear and collision noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wave washers with curved or inclined contact surfaces are used, then the structure is simple and easy to manufacture, but the contact area with parts is small leading to high surface pressure and rapid wear
Solution Approach 1:
The wave washer incorporates protruding pieces with flat surfaces at specific locations where contact with parts occurs. This local modification concentrates the design effort on the contact regions only, providing large contact areas and low surface pressure where needed, while maintaining the simple wave-shaped body structure in non-contact regions. This resolves the contradiction by improving wear resistance locally without requiring complex overall restructuring.
Solution Approach 2:
The invention transitions from conventional curved or inclined contact surfaces to flat surfaces that extend in the axial direction. This dimensional change from point/line contact to face contact dramatically increases the contact area. The flat surfaces on the protruding pieces create a new dimension of contact area that was not present in conventional designs, thereby reducing surface pressure and wear without complicating the manufacturing process.
2Object-affected harmful factors
If conventional wave washers with small contact areas are used, then the structure remains simple, but collision noise occurs between parts due to insufficient cushioning
Solution Approach 1:
The wave washer is positioned between moving parts to provide cushioning before collision occurs. The protruding pieces with flat surfaces ensure consistent contact and distribute forces evenly, preventing sudden impacts. This beforehand cushioning approach reduces collision noise by maintaining continuous contact and absorbing shocks before they can cause harmful noise, while keeping the structure relatively simple through the wave-shaped design.
3Duration of action of stationary object
If conventional wave washers are used, then manufacturing is easy, but the contact surfaces experience high stress leading to rapid deterioration of springiness
Solution Approach 1:
The flat surfaces on the protruding pieces are provided only at the contact regions where high stress occurs. This local quality enhancement protects the critical contact areas from wear and stress concentration, extending service life. The rest of the wave washer body maintains its simple wave-shaped structure that is easy to manufacture, thus resolving the contradiction between durability and manufacturing ease.
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 effectively reduces wear on the wave washer and minimizes collision noise in variable-flow-rate valves by increasing the contact area and distributing surface pressure uniformly, enhancing the durability and noise reduction of the turbocharger.
Implementation Method 1
The body which is formed in a wave shape has springiness and is deformed (contracted) in the axial direction while being disposed between two parts
Implementation Method 2
the contact area between the wave washer and the part is increased. Accordingly, surface pressure is decreased as compared with a washer having the same inner and outer diameters. Accordingly, wear due to contact with parts can be reduced
Data Source
AI summary
A wave washer according to an aspect of the present disclosure includes an annular body which is formed around an axis into a wave shape and at least one protruding piece which protrudes inward or outward from the body. The at least one protruding piece includes a flat surface which is perpendicular to the axis.