Introducing The InterShim™ Wave Spring: The Customizable Spring for Demanding Rotational Requirements

Wave springs are commonly used for space saving, offering up to 50% axial space savings in an application. They are also frequently used in the axial preloading of bearings, however, in high-performance applications like electric mobility, traditional designs can struggle with high acceleration and torsional forces leading to bearing damage and instability. Rotor Clip has developed the InterShim™ Wave Spring to meet the demands of such environments, providing a reliable solution that excels under high-acceleration conditions.

The InterShim™ Wave Spring is specifically engineered for applications with demanding high acceleration and rotation, such as electric drives, where frequent acceleration and deceleration occur. Unlike traditional wave springs, which can be prone to torsional instability, the InterShim™ spring features alternating active (wavy) and inactive (flat) coils. This unique patented design allows the spring to withstand torsional loads and high acceleration, ensuring precise and reliable performance when rotational movement is present.

Key Benefits of the InterShim™ Wave Spring:

1. Torsional Stability: The alternating design of active and inactive turns allows the spring to twist without losing spring force, preventing collapse or deformation during extreme acceleration and rotation.
2. Surface Protection: The spring features either floating ends or floating bent ends, designed to remain axially and radially stable, preventing them from migrating into the bearing cage. This feature minimizes the risk of point loading and protects the bearing from unnecessary damage.
3. Customizable Design: The InterShim™ Wave Spring can be customized to meet specific requirements. Typical modifications include adjusting wave count, coil arrangement, and material selection for applications needing higher preload force or a softer spring rate.
4. Increased Efficiency: By eliminating the need for additional spacers or complex components, the InterShim™ simplifies assembly, reducing production costs and enhancing efficiency.

How It Works

• The design of the turn’s changes from inactive (flat shims) to active (waved) in alternation, with an inactive turn always followed by an active turn.
• Every inactive turn between active turns acts like a shim washer between two spring elements. This prevents the wave trough of a higher-level active turn from moving onto the wave crest of a lower-level active turn due to displacement or circumferential movement caused by torsional loads.
• The turns of the wave spring, arranged with flat or waved shapes, are engineered to smoothly glide against each other. This design prevents the wave spring from collapsing, even when subjected to torsional loads that create relative movement between the active (waved) turns.
• Torsional resistance is enhanced by inactive turns between layers.

While originally developed for electric mobility applications, the InterShim™ Wave Spring’s design makes it an ideal choice for a variety of industries like aerospace, energy, industrial machinery, and medical technologies. Whether used in high-speed drives, off-highway vehicles, or other challenging environments, the InterShim™ Wave Spring offers a reliable and long-lasting solution that supports the success of your application.

Rotor Clip’s expertise in wave spring design and in-house manufacturing enables us to deliver Application Driven Solutions that meet the specific demands of modern industries. From initial prototype development to full-scale production, we handle every step in-house, ensuring consistency and quality throughout.  With a commitment to quality standards and precise manufacturing processes, Rotor Clip provides reliable wave spring solutions for nearly every application.

We ensure the InterShim™ Wave Spring is not just an innovation, but a reliable tool for meeting the evolving needs of engineers and manufacturers across industries. Contact us now to learn more.