Apparatus and method for encapsulating a disc spring assembly in an insulated package
An apparatus for encapsulating a disc spring assembly in an insulated package, wherein the apparatus includes at least a disc spring assembled in a cylindrical stack; an internal guide bushing passing through a center of the at least a disc spring, wherein the internal guide bushing is configured to constrain the at least a disc spring; a first end bushing and a second end bushing, wherein each of the first end bushing and the second end bushing includes a circumferential groove, wherein a top portion of the at least a disc spring is abutting against the first end bushing, and wherein a bottom portion of the at least a disc spring is abutting against the second end bushing; and an insulation layer, wherein the insulation layer is configured to encapsulate the at least a disc spring and at least a portion of the first and the second end bushings.
1 . An apparatus for encapsulating a disc spring assembly in an insulated package, wherein the apparatus comprises:
at least a disc spring assembled in a cylindrical stack;
an internal guide bushing passing through a center of the at least a disc spring, wherein the internal guide bushing is configured to constrain the at least a disc spring;
a first end bushing and a second end bushing, wherein each of the first end bushing and the second end bushing comprises a circumferential groove, wherein a top portion of the at least a disc spring is abutting against the first end bushing, and wherein a bottom portion of the at least a disc spring is abutting against the second end bushing; and
an insulation layer, wherein the insulation layer is configured to encapsulate the at least a disc spring, and at least a portion of the first and the second end bushings.
2 . The apparatus of claim 1 , wherein the insulation layer comprises an insulative shrink tubing.
3 . The apparatus of claim 2 , wherein the insulative shrink tubing comprises polyvinyl chloride, polyethylene, and silicone rubber.
4 . The apparatus of claim 2 , wherein the insulation layer is configured to mitigate sudden release of stored energy in the at least a disc spring.
5 . The apparatus of claim 1 , wherein the insulation layer is captured by a circumferential groove in the first end bushing and the second end bushing providing a capture force during initial assembly of the at least a disc spring assembly.
6 . The apparatus of claim 5 , wherein the capture force is resistant to an acceleration of the at least a disc spring assembly.
7 . The apparatus of claim 5 , wherein the capture force provided by the insulation layer is maintained after repeated compression and decompression cycles and resists lateral loads, vibration, and shocks encountered during shipping, handling, and installation, without materially influencing a compression characteristics of the at least a disc spring.
8 . The apparatus of claim 1 , wherein the at least a disc spring are configured to manage mechanical loads in a next higher assembly.
9 . The apparatus of claim 8 , wherein the next higher assembly comprises an electrolyzer assembly.
10 . The apparatus of claim 8 , wherein the at least a disc spring are configured to provide an operational pressure adjustment in the next higher assembly.
11 . The apparatus of claim 8 , wherein the at least a disc spring is configured to provide mechanical support under varying thermal conditions in the next higher assembly.
12 . The apparatus of claim 8 , wherein the apparatus is configured to maintain a preload force despite creep, relaxation, and thermal cycling of adjacent structural components in a next higher assembly.
13 . The apparatus of claim 1 , wherein the first end bushing and the second end bushing are configured to resist unwanted deflection by compression of the at least a disc spring into a surface of the first end bushing and the second end bushing.
14 . The apparatus of claim 1 , wherein a length of the internal guide bushing is selected to ensure continuous engagement of at least a disc spring and full capture at both ends by the first end bushing and the second end bushing across an entire compression range of the apparatus and without interference.
15 . The apparatus of claim 1 , wherein the at least a disc spring, wherein the at least a disc spring is configured to provide a pre-determined load-deflection relationship by achieving a stiffness and a corresponding allowable deflection range based on an orientation of the at least a disc spring.
16 . The apparatus of claim 1 , wherein the apparatus is configured to ensure uniform radial constraint of the at least a disc spring, and reduce variance in load-deflection response across production lots.
17 . The apparatus of claim 1 , wherein the at least a disc spring comprises at least a conical disc spring and at least a wave disc spring.
18 . The apparatus of claim 1 , wherein the internal guide bushing comprises one or more of steel, aluminum, and plastic material.
19 . The apparatus of claim 1 , wherein the first end bushing and the second end bushing are positioned between the at least a disc spring and a mounting surface and a nut.
20 . The apparatus of claim 1 , wherein first end bushing and the second end bushing are configured to interface directly with coolant or gas manifold structures of an electrolyzer, and distribute compressive loads while preventing localized deflection.
21 . The apparatus of claim 1 , wherein the first end bushing and the second end bushing are configured to maintain proper spacing and alignment of the apparatus.
22 . The apparatus of claim 1 , wherein a height of the first end bushing and the second end bushing is configured to provide localized structural thickness in a next higher assembly endplate.
23 . The apparatus of claim 1 , wherein the insulated package is configured to be compression tested as a unit to verify stiffness, deflection, and load characteristics with repeatability across production batches, without requiring inspection of at least a disc spring.
24 . The apparatus of claim 1 , wherein the internal guide bushing provides a smooth buffer surface along tie rod threads of a next higher assembly to prevent direct interaction between the at least a disc spring and the tie rod threads during compression.
25 . The apparatus of claim 1 , wherein the apparatus is configured for modular replacement within a next higher assembly, allowing for pre-assembled spring modules to be interchanged without disassembling individual components.
26 . The apparatus of claim 1 , wherein the encapsulation permits non-destructive testing of compression behavior by compression cycling of the apparatus.
27 . The apparatus of claim 1 , wherein the apparatus is further configured for batch testing by automated equipment, enabling statistical process control of stiffness and deflection values.
28 . The apparatus of claim 1 , wherein the apparatus provides preload management to accommodate dimensional changes of membrane electrode assemblies in an electrolyzer stack during hydration or thermal expansion.
29 . An apparatus for encapsulating a disc spring assembly in an insulated package, wherein the apparatus comprises:
at least a disc spring assembled in a cylindrical stack;
a temporary guide fixture passing through a center of the at least a disc spring, wherein the temporary guide fixture is configured to constrain the at least a disc spring;
a first end bushing and a second end bushing, wherein each of the first end bushing and the second end bushing comprises a circumferential groove, wherein a top portion of the at least a disc spring is abutting against the first end bushing, and wherein a bottom portion of the at least a disc spring is abutting against the second end bushing; and
an insulation layer, wherein the insulation layer is configured to encapsulate the at least a disc spring, and at least a portion of the first and the second end bushings.