The Carbon Composite Bellows™ Spring (CCBS) is a system of carbon fibre elements that combine to work as a high performance, light weight and design flexible compression spring.  Using carbon fibre to its best advantage, the design is focused on replacing conventional coil springs or metallic Belleville disc springs. A functional CCBS spring is made from several individual elements, paired in sets and joined to make a stack.  By allowing deflection, with a central shaft, the spring elements sit on each and the spring rate of the stack is determined by the number of elements, the base rate of each element, and their series or parallel orientation in the stack.

Most importantly the CCBS system, offers not only a tunable spring rate through compression, whether digressive or progressive, but can save up to  a 60-70% weight when compared with a similar metallic spring size. The Carbon Composite Bellows Spring offers new solutions to old challenges. 

Why Carbon Fibre?

Carbon fiber composite material offers significant advantages compared to conventional metallic alloys when used as a spring material.

  • The manufacture of carbon fibre parts is through molding. This allows for complicated and intricate designs to be formed in a single operation and permits design features not possible with a machined or stamped metallic part.
  • Laminate construction permits steeper pitch angles to allow more deflection per element without overstressing.
  • The base rate of each element is determined by its finished thickness. This means new or custom rates can be built quickly and do not require the use of different raw material sizes or special tooling.
  • Carbon fibre is non-magnetic and impervious to many liquids and compounds that lead to metallic corrosion.
  • For a given rate and deflection, a CCBS stack weighs significantly less - often up to 60-70%!

CCBS stack on an automotive shock assemblyBenefits of a CCBS Stack 

  • Adaptable - The shape of the rate curve is able to be tuned to meet the needs of the project without a costly redesign or even the manufacture of new parts. It is simply a reorientation of the standard elements.
  • Squareness under load - As the carbon elements work in bending, instead of torsion, to store and release energy, the parallel ends of the spring remain parallel throughout the deflection.
  • In-the-field Design Flexibility - The ability to change the spring rate, length, and deflection of a CCBS stack on the fly, without any new manufacturing, means that you have ultimate control over the spring used in your product.
  • Mechanically Efficient - Low hysteresis due to an optimized interface between the elements and the reduction of friction at the spring-seat surface results in a spring that is as efficient at releasing energy as it is at storing it.

Possible Applications and Uses for CCBS

  • Weight-conscious projects
  • Motorsports
  • Aerospace
  • SatellitesCarbon Composite Bellows Spring elements and stack
  • Outdoor Recreation
  • High Performance Activities
  • General Industry
  • Steady Camera
  • Prosthetics

Key Considerations for CCBS:

  • Overall dimensional constraints: ID, OD, and free length
  • Deflection vs. free length
  • Required rate or range of rates
  • Environmental effects: UV exposure, cleanliness, and temperature
  • Service life/cycles and frequency of inspection

Give us a call on 01386 421005 to see how the CCBS product can help with your design challenges.

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