Patent Publication Number: US-11649870-B2

Title: Vibration isolator with flexible housing

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 63/110,671, filed on Nov. 6, 2020, which is herein incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates to mechanisms for isolating components from vibrations and, more particularly, for isolating a second component from vibrations experienced by a first component which is mechanically coupled to the second component. 
     BACKGROUND 
     It has been found that low frequency vibrations (in the range 0-10 Hz) experienced by a vehicle traveling along a road surface can be especially irritating to vehicle occupants. Forces resulting from these vibrations may be transmitted from the vehicle chassis to seats where the occupants are sitting. It can be difficult to isolate the passenger seats from these vibrations. Currently-used methods of isolating vehicle seats from such vibrations may be complex and expensive. In addition, in certain applications, vibration isolators may be subjected to side loading or torsional loading which acts to urge a portion of the isolator in a direction away from a central axis of the isolator in an unloaded condition. 
     SUMMARY 
     In one aspect of the embodiments described herein, a vibration isolator is provided including a first conical disc spring member having a first end and a second end opposite the first end. A first-end spacer in contact with the first spring member first end, and a second-end spacer in contact with the first spring member second end. A second conical disc spring member has a first end and a second end opposite the first end. The second spring member first end is in contact with the first-end spacer. Another second-end spacer is in contact with the second spring member second end. The isolator also includes a flexible housing defining an interior. The housing is in contact with and extends between the second-end spacer and the other second-end spacer so that the first-end spacer and the first and second spring members are received in the housing interior. The housing includes a plurality of spaced-apart through holes formed therealong between the second-end spacer and the other second-end spacer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various systems, methods, and other embodiments of the disclosure. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one embodiment of the boundaries. In some embodiments, one element may be designed as multiple elements or multiple elements may be designed as one element. In some embodiments, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale. 
         FIG.  1    shows a schematic side cross-sectional view of one embodiment of a vibration isolator (generally designated  12 ) in accordance with an embodiment described herein. 
         FIG.  2    is the isolator view of  FIG.  1    showing resilient deformation of the isolator responsive to an applied axial load. 
         FIG.  3    is the view of  FIG.  2    showing resilient lateral bending or angular deflection of a portion of the isolator with respect to a central axis of the isolator, responsive to application of a sideways load and/or a torsional load to a portion of the isolator. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments described herein relate to a vibration isolator for isolating a second component from vibrations experienced by a first component which is mechanically coupled to the second component. The isolator includes at least a first conical disc spring member having a first end and a second end opposite the first end. A first-end spacer in contact with the first spring member first end, and a second-end spacer in contact with the first spring member second end. A second conical disc spring member has a first end and a second end opposite the first end. The second spring member first end is in contact with the first-end spacer. Another second-end spacer is in contact with the second spring member second end. The isolator also includes a flexible housing defining an interior. The housing is in contact with and extends between the second-end spacer and the other second-end spacer so that the first-end spacer and the first and second spring members are received in the housing interior. The housing includes a plurality of spaced-apart through holes formed therealong between the second-end spacer and the other second-end spacer. The isolator may include conical disc spring members and associated spacers as needed, according to the requirements of a particular isolator application. The use of a flexible housing with through holes enables the isolator to resiliently laterally deflect to a certain degree to provide a degree of positional compliance in response to lateral and/or torsional loads acting on the isolator. 
       FIG.  1    shows a schematic side cross-sectional view of one embodiment of a vibration isolator (generally designated  12 ) in accordance with an embodiment described herein. Unless otherwise described herein (for example, with regard to features of and related to housing  40 ), the vibration isolator  12  may have the same basic structure and operation as an isolator described in any of commonly-owned U.S. Pat. No. 10,677,310 (“the &#39;310 patent”), commonly-owned U.S. Pat. No. 10,371,229 (“the &#39;229 patent”), or commonly-owned U.S. patent application Ser. No. 15/841,978, the disclosures of which are incorporated by reference herein in their entireties. The vibration isolator  12  may be structured and positioned for limiting transfer of vibrations from a first element to a second element coupled to the first element. The vibration isolator  12  may be interposed between elements of a system or mechanism to vibrationally isolate the elements from each other, so that transmission of vibrations experienced by the first element of the system or mechanism to the second element of the system or mechanism is attenuated or eliminated. For example, in operation, the vibration isolator  12  may be incorporated into a vehicle (not shown) so as to help isolate a second element  14  ( FIG.  1   , for example, a vehicle seat assembly) from vibrations experienced by a first element  16  (for example, a vehicle chassis) during movement of the vehicle along a road surface. The vibration isolator  12  is shown in  FIG.  1    in an unloaded and undeflected condition (i.e., without any loads applied to the isolator from exterior of the isolator). The isolator  12  may have a first end  12   a  and a second end  12   b  opposite the first end. In one or more arrangements, the isolator  12  is generally cylindrical and has a central axis X 1  extending therethrough. 
     Although the design and operation of the vibration isolator embodiments disclosed herein have been described as applied to a vehicle seat assembly, design particulars of an isolator structure described herein may be adapted to isolate or insulate numerous types of mounted mechanisms or elements from vibrations experienced by mounting structures to which the mounted mechanisms or elements are coupled, and a vibration isolator structured in accordance with the principles described herein may be employed in a variety of other applications. For example, vehicle engines and transmission differentials may be vibrationally isolated from a vehicle frame. Non-vehicle applications may include mounting systems for equipment in manufacturing plants. 
     In general, details of the isolator internal elements and element relationships will be described with reference to the highlighted region  100  of  FIG.  1   . However, it will be understood that, in one or more arrangements, the elements and element relationships in the other portions of the isolator shown in  FIG.  1    are the same as or repetitions of the elements and relationships shown in region  100 . 
     The vibration isolator  12  may include a plurality of conical disc spring members, generally designated  20 . The conical disc spring members  20  may have the same shape and dimensions, or the conical disc spring members  20  may have different shapes and dimensions. The conical disc spring members  20  shown in  FIG.  1    have the same shapes and dimensions within the limits of manufacturing tolerances. In other arrangements, more (or fewer) conical disc spring members and spacers as described herein may be provided to vary the dimensions and/or dynamic response of the isolator  12  as desired. Similarly, conical disc spring members  20  having differing individual force-deflection characteristics may be utilized in the isolator to vary the dimensions and/or dynamic response of the isolator as desired. 
     In embodiments described herein, each of the conical disc spring members  20  may have a structure, dynamic response, and other characteristics which are the same as those of conical disc spring members described in the aforementioned &#39;310 or &#39;229 patents. The general shape of the spring members is known in the pertinent art in the form of a Belleville washer or conical disc washer, for example. 
     Referring to  FIG.  1   , the vibration isolator  12  may include a first conical disc spring member  20 - 1  and a second conical disc spring member  20 - 2 . The first conical disc spring member  20 - 1  may have a first end  20   a - 1  including a central opening  20   b - 1  of the conical disc spring member  20 - 1 , and a second end  20   c - 1  opposite the first end  20   a - 1 . The second end  20   c - 1  defines a circular base  20   d - 1  of the conical structure. A central axis  20   e - 1  of spring member  20 - 1  extends through a center of the central opening  20   b - 1  and also through a center of the circular base  20   d - 1 . Also, the second conical disc spring member  20 - 2  may have a first end  20   a - 2  including a central opening  20   b - 2  of the conical disc spring member  20 - 2 , and a second end  20   c - 2  opposite the first end  20   a - 2 . The second end  20   c - 2  defines a circular base  20   d - 2  of the conical structure. A central axis  20   e - 2  of spring member  20 - 2  extends through a center of the central opening  20   b - 2  and also through a center of the circular base  20   d - 2 . The central axis  20   e - 1  of spring member  20 - 1  may be coaxial with the central axis X 1  of the isolator  12  when the isolator is in an unloaded condition. Similarly, the central axis  20   e - 2  of spring member  20 - 2  may be coaxial with the central axis X 1  of the isolator  12  when the isolator is in an unloaded condition. 
     A suitably-structured spacer may be interposed between each two adjacent conical disc spring members  20 . The spacer may be structured to engage each of the adjacent conical disc spring members so as to maintain a predetermined spacing between portions of the adjacent conical disc spring members during loading of the conical disc spring members. The spacers may also be designed to increase the deflection which may be achieved by the vibration isolator energy-absorbing structure during loading, by providing space for the conical disc spring members in contact with the spacer to flatten under loading as shown in  FIG.  2   , thereby providing a degree of quasi-zero/negative stiffness response as described in the aforementioned &#39;310 and &#39;229 patents. A spacer may also be positioned at each end of a stack of conical disc spring members as described herein, to support portions of associated conical disc spring members. 
     For purposes described herein, two conical disc spring members are understood to reside adjacent each other when the spring members are positioned immediately next to each other, with no additional spring member between the two spring members. Any spacers described herein may act to space apart portions of adjacent conical disc spring members and/or to space portions of conical disc spring members apart from other parts of the isolator and/or elements exterior of the isolator. In one or more arrangements, and as described herein, loads may be applied to the isolator spring members using one or more spacers or other elements configured to interface with elements exterior of the isolator. 
     Referring again to  FIG.  1   , a second-end spacer  22 - 1  may have a base portion  22   a - 1  with a first side  22   b - 1  and a second side  22   c - 1  opposite the first side  22   b - 1 . The first conical disc spring member second end  20   c - 1  may be positioned in contact with the second-end spacer base portion second side  22   c - 1 . The first conical disc spring member second end  20   c - 1  may be received in a cavity formed by the base portion second side  22   c - 1  and a wall  22   d - 1  extending along an outer edge  22   f - 1  of the second-end spacer  22 - 1 . A similar cavity may be formed along the first side  22   b - 1  of the base portion  22   a - 1  for receiving therein a second end  20   c - 3  of another conical disc spring member  20 - 3 . “Contact” between two or more elements as described herein may include direct physical contact and indirect contact through an intermediate element(s) interposed between the two or more elements. 
     A first-end spacer  24 - 1  may be positioned in contact with the first conical disc spring member first end  20   a - 1  and also with the second conical disc spring member first end  20   a - 2 . First-end spacer  24 - 1  may include one or more shoulders  24   s - 1  structured to engage the first end  20   a - 1  of first conical disc spring member  20 - 1  as shown, adjacent the central opening  20   b - 1  formed in the spring member first end. One or more additional shoulder(s)  24   s - 1  may also be structured to engage a first end of second conical disc spring member  20 - 2  as shown, adjacent a central opening  20   b - 2  formed in the second conical disc spring member first end  20   a - 2 . 
     Another second-end spacer  22 - 2  may also be positioned in contact with the second spring member second end  20   c - 2 . Referring again to  FIG.  1   , other second-end spacer  22 - 2  may have a base portion  22   a - 2  with a first side  22   b - 2  and a second side  22   c - 2  opposite the first side  22   b - 2 . The second conical disc spring member second end  20   c - 2  may be positioned in contact with the second-end spacer base portion first side  22   b - 2 . The second conical disc spring member second end  20   c - 2  may be received in a cavity formed by first side  22   b - 2  and a wall  22   d - 2  extending along an outer edge  22   f - 2  of the other second-end spacer  22 - 2 . A similar cavity may be formed along the second side  22   c - 2  of the base portion  22   a - 2  for receiving therein a second end  20   c - 4  of yet another conical disc spring member  20 - 4 . Second-end spacers  22  may be structured to provide one or more bearing surfaces (such as wall  22   d - 2 ) along their outer edges  22   f  that are usable for establishing and maintaining contact with portions of the isolator housing  40 , as described herein. 
     As seen in  FIG.  1   , the isolator may also include conical disc spring members and spacers in addition to those just described. 
     The first-end spacers  24  incorporated into the isolator  12  may have the same configurations or different configurations. In the embodiment shown, first-end spacers  24 - 1  and  24 - 2  have the same configurations. Thus, the description of first-end spacer  24 - 1  set forth herein also applies to spacer  24 - 2  and any other similarly configured spacers that may be incorporated into an embodiment of the vibration isolator. Similarly, the second-end spacers  22  incorporated into the isolator may have the same configurations or different configurations. Second end spacers  22 - 1  and  22 - 2  shown in  FIG.  1    have the same configurations. Thus, the description of spacer  22 - 1  set forth herein also applies to spacer  22 - 2  and any other similarly configured spacers that may be incorporated into an embodiment of the vibration isolator. 
     Embodiments of the vibration isolator described herein may be structured to provide a quasi-zero/negative stiffness response to a force applied to the vibration isolator when the force applied to the isolator is within an associated predetermined range. Also, each conical disc spring member may be structured to provide a quasi-zero/negative stiffness response to a force applied to the spring member when a force applied to the spring member is within an associated predetermined range. Characteristics of the conical disc spring members and other elements of the isolator  12  needed to provide quasi-zero/negative stiffness responses of the isolator and of individual conical disc spring members are described in detail in the aforementioned &#39;310 and &#39;229 patents. 
     Referring to  FIGS.  1 - 3   , in one or more arrangements, the vibration isolator  12  may include a flexible housing  40  having a first end  40   a  and a second end  40   b  positioned opposite the first end  40   a.  At least one wall  40   c  may extend between the first and second ends  40   a,    40   b.  The first end  40   a,  second end  40   b,  and at least one wall  40   c  may combine to define an interior  40   d  of the housing. 
     The term “flexible” as applied to housing  40  means that the housing is capable of bending axially and as shown in  FIG.  2   . The term “flexible” also means that housing  40  is also capable of bending laterally as shown in  FIG.  3    responsive to loads which tend to deflect a portion of the isolator (for example, first end  12   a  of the isolator) in a direction away from the central axis X 1  of the isolator. Such a tendency to bend may arise, for example, from a torsional load T 1  ( FIG.  3   ) applied to the isolator or from a lateral load F 2  ( FIG.  3   ) applied to the isolator at or near an end of the isolator and having a component in a direction D 2  extending perpendicular to axis X 1 . In embodiments, the housing  40  may be formed from a rubber or polymeric material suitable for the applications described herein. 
     Each combination of conical disc spring members  20  and spacers  22 ,  24  inside the housing  40  in a given embodiment of the vibration isolator forms an associated energy-absorbing structure incorporated into the housing. Housing  40  may contain and/or be in contact with the deflectable and movable components (such as conical disc spring members  20  and spacers  22 ,  24  described herein) forming the energy-absorbing structure of the isolator. As stated previously, the isolator  12  may be coupled to other, exterior elements (not shown) to mitigate or eliminate transmission of vibration between the other elements. 
     Referring again to  FIG.  1   , the housing  40  may be in contact with and extend between the second-end spacer  22 - 1  and other second-end spacer  22 - 2  so that at least the first-end spacer  24 - 1  and the first and second spring members  20 - 1 ,  20 - 2  are received in the housing interior  40   d.  In arrangements including additional spacers and conical disc spring members, the housing  40  may be structured to extend between the second-end spacers located closest to respective ends of the isolator (e.g. spacers  22 - 1  and  22 - 3  in  FIG.  1   ). Thus, in the embodiment shown in  FIG.  1   , the housing  40  extends between second-end spacers  22 - 1  and  22 - 3 , thereby containing the first-end spacers  24 - 1 ,  24 - 1  and all of conical disc spring members  20 - 1 ,  20 - 2 ,  20 - 4  and  20 - 5  within the housing interior  40   d.    
     In one or more arrangements, to enhance the flexibility of the isolator housing  40 , the housing  40  may include a plurality of spaced-apart through holes  42  formed therealong between the second-end spacer  22 - 1  and other second-end spacer  22 - 2 . In embodiments such as shown in  FIG.  1    with multiple first-end spacers  24  and additional second-end spacers  22  and conical disc spring members  20 , through holes  42  may be formed in the housing  40  between each pair of adjacent second-end spacers  22 . It has been found that the holes  42  increase the ability of the housing  40  to deflect and bend as shown in  FIGS.  2 - 3   . 
     In particular arrangements, the through holes  42  formed in the housing may be circular. In particular arrangements, the through holes  42  may be formed in the housing so as to be coaxial along an axis H 1  extending along the housing wall  40   c  and along a plane structured to be perpendicular to the isolator axis X 1  when the isolator  12  is unloaded. 
     In particular arrangements, each of the through holes  42  has a diameter DH in the range of 0.3×D3-0.8×D3, where D3=a minimum spacing between the second end spacer  22 - 1  and the other second-end spacer  22 - 2  when the vibration isolator  12  is in an undeflected condition as shown in  FIG.  1   . In more particular arrangements, each of the through holes has a diameter DH in the range of 0.3×D3-0.4×D3. 
     In particular arrangements, all of the through holes  42  may have equal diameters (within applicable tolerance limits). In more particular arrangements, a minimum spacing D 4  between adjacent through holes of each pair of adjacent through holes is equal to the diameter of the through holes  42 . The spacing D 4  may be a spacing between closest edges of the adjacent holes  42  taken along an exterior surface of the housing  40 . 
     In particular arrangements, the housing  40  may be formed from a length of suitably dimensioned heat-shrinkable tubing processed so as to form an interference fit with the second-end spacer  22 -land the other second end spacer  22 - 2  along outer edge portions of the second-end spacers  22 - 1 ,  22 - 2 . The interference fits between the tubing and the second-end spacers may aid in keeping the conical disc spring members and spacers in contact with each other, thereby maintaining the structural integrity of the assembled spring/spacer structure. In one or more arrangements, the tubing may include a heat-softenable adhesive material positioned along interior surfaces of the tubing, to aid in securing the tubing to outer edges of the second-end spacers after the tubing is applied to the spring/spacer assembly. 
     In particular arrangements, the holes  42  may be formed in the tubing prior to application of the tubing to the assembled spring/spacer structure to form the housing. The spacings to be provided between the holes  42  may be determined according to the particular dimensions of the assembled spring/spacer structure. In other arrangements, the holes may be formed in the housing material after application of the housing material to the assembled spring/spacer structure. 
     It has been found that the degree of shrinkage of the tubing may be controlled by suitable application of heat to ensure contact between the tubing and the second-end spacers and to exert a degree of control over the stiffness of the housing. Specifically, the stiffness of the housing may be increased if desired by increasing the amount of shrinkage of the tubing around the assembled spring/spacer structure. 
     In particular arrangements, the housing  40  may include at least one lip overlapping a corner of an associated one of the second-end spacers. In the embodiment shown in the drawings, lips  40   g,    40   h  are formed at respective ends of the housing  40 . In an embodiment of the housing formed from heat-shrinkable tubing, the lips  40   g,    40   h  may be formed by providing a length of tubing slightly longer than the unloaded assembled spring/spacer structure. When heat is applied to contract the lip portions of the housing, the lips  40   g,    40   h  may overlap the corners of the second-end spacers at each end of the assembled spring/spacer structure. The assembled spring/spacer structure may be slightly axially compressed between the lips  40   g,    40   h  to help keep the structure together during loading, when unloaded, and also during transport prior of the isolator. In embodiments without one or more lips, tubing shrinkage dimensions may be controlled to provide interference fits with the second end spacers  22  sufficient to maintain contact between the tubing and the second-end spacers. 
     The structures of the conical disc spring members  20  and the spacers  22 ,  24  at the contact interfaces between the spring members and spacers may be configured to facilitate transfer of forces between the conical disc spring members and the spacers and to help maintain contact between the isolator elements as shown in the drawings, responsive to forces exerted on the conical disc spring members  20  and the spacers by the housing  40  as described herein. 
     Flexibility of the housing  40  may be controlled by suitable modification of the number, dimensions and/or arrangements of holes  42 , the thickness and composition of the housing material, and the degree of shrinkage (in a heat-shrinkable tube application). Referring to  FIGS.  1  and  2   , a force application member(s)  14  (such as a portion of a vehicle seat assembly or an intermediate part separate from the seat assembly) may enable forces to be transferred from an exterior of the isolator  12  to the energy-absorbing structure located in the housing interior  40   d.  As shown in  FIGS.  1  and  2   , a force application member  14  may contact a spacer  25  inside the housing to deflect the isolator  12 . The spacer  25  may be structured to engage a portion of an associated conical disc spring member  20 - 3  adjacent a central opening in a first end of the conical disc spring member  20 - 3 , to enable application of a force to a first end of the conical disc spring member. 
     As previously described, flexible housing  40  is also structured to enable the housing to bend as shown in  FIG.  3   . Responsive to loads which tend to deflect a portion of the isolator (for example, first end  12   a  of the isolator) in a direction away from the central axis X 1  of the isolator. Such a tendency to bend may arise, for example, from a torsional load T 1  applied to the isolator and/or from a lateral load F 2  applied to the isolator at or near an end of the isolator in a direction D 2  perpendicular to axis X 1 . In many applications, a lateral load F 2  and/or a torsional load T 1  may be applied to the isolator in addition to the axial load component F 1  applied in direction D 1  as shown in  FIG.  2   . 
       FIG.  2    shows resilient deformation of the isolator  12  responsive to application of a load F 1  along the axis X 1  of the isolator. As seen in the drawing, the flexible housing  40  may be structured to deform such that portions of the housing extending between adjacent ones of the second-end spacers  22  deflect inwardly toward the housing interior and into spaces between the adjacent second-end spacers. Withdrawal of the axial load F 1  may enable the isolator to return to the unloaded shape shown in  FIG.  1   . 
     In one or more arrangements, an isolator  12  structured as shown in the drawings and including an embodiment of a perforated housing  40  as described herein may have an end (for example, first end  12   a ) which is rotatable up to an angle of θ relative to the unloaded isolator axis X 1 . In one or more arrangements, the isolator may be structured to bend to a maximum bend angle θ of 10° with respect to the isolator central axis. 
     The flexible structure of the housing  40  enables the isolator  12  to resiliently bend to comply to some degree with torsional and lateral loading and the resulting displacements of portions of the isolator, while maintaining the lateral stability and structural integrity of the isolator. Bearing forces exerted by the housing  40  on the second-end spacers  22  aid in preventing the various spacers and conical disc spring members from separating or losing contact with each other in the housing interior while the isolator  12  is both unloaded and loaded. 
     Detailed embodiments are disclosed herein. However, it is to be understood that the disclosed embodiments are intended only as examples. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the aspects herein in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of possible implementations. Various embodiments are shown in  FIGS.  1 - 3   , but the embodiments are not limited to the illustrated structure or application. 
     The terms “a” and “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The phrase “at least one of . . . and . . .” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. As an example, the phrase “at least one of A, B, and C” includes A only, B only, C only, or any combination thereof (e.g., AB, AC, BC or ABC). 
     Aspects herein can be embodied in other forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope hereof.