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Belleville washer or Belleville disc springs have a conical shape that generates a high force in a concise spring length and minimal movement when compressed. Belleville washers' advantages include high load capacity within a small space, shock absorption, dampening functionality, high tension maintained in bolted applications, and load characteristics that can be modified by stacking.
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Disc springs are used in several industries and applications. They are ideal in situations where tension is lost due to thermal expansion or contraction, compression set, or when wear of parts occurs. Belleville washers and disc springs are unique because they exert a constant uniform pressure and are perfect for multiple assemblies used for drilling, stabilization, and shock absorption.
Depending on your application's needs, you can consider using Belleville washers singly or in stacks. Your configuration will depend on your desired load and travel. In most cases, Belleville washers perform best in high load and short-travel conditions, such as those used in confined spaces. If stacking disc springs, you can use parallel or series stacking configurations.
Also known as coned-disc springs or cupped spring washers, these parts have a conical shape with a hole in the middle and can be loaded either statically or dynamically. Their cup-like shape provides several benefits, including:
Typically, a washer will be used to evenly distribute clamping force from a threaded fastener over a wider area, which is necessary for electrical conductivity. Also, a Belleville washer can absorb shock and keep the fastener tight.
To fully grasp the importance of material input quality, we need to first review the relationships between metals and electricity.
Typically, an electrical connection will be composed of different types of metals—each one will have its own thermal expansion coefficient. That means when the temperature increases or decreases, the various metals will experience changes in volume (expansion or contraction) at different rates.
For instance, the thermal expansion coefficients for copper and aluminum for each centigrade degree increase are 17∙10E-6 and 23∙10E-6, respectively. So, aluminum will experience 35% more thermal expansion than copper.
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Why does that matter?
Put simply, the difference in thermal expansion can threaten the structural integrity of the electrical connection. With certain pieces expanding faster than others, the load on the bolt may increase, which, in turn, causes the joint components to loosen.
A reduced bolt load leads to increased electrical joint resistance, which could result in minor issues like hot spots or even major problems like the catastrophic failure of the electrical system.
One of the most important functions for Belleville washers is to properly secure electrical fasteners. However, their efficacy is highly contingent on the quality of materials.
When it comes to electrical systems that experience massive temperature swings, you can’t just use any old Belleville washer. The materials matter. It needs to be designed to meet the electrical power transmission and distribution requirements of that specific application.
For example, a circuit breaker will likely have different size, material grade, and finish requirements from a busbar.
The right Belleville washer—one made of materials that are up to spec—makes it possible to maintain a consistent load on the joint at all times, no matter where the electrical system may be in its thermal cycle. This promotes safety and power efficiency.
A Belleville washer may be small, but it can have an enormous impact on electrical connections. However, to be as effective as possible, the washer materials must align with the job requirements.
That’s where American Belleville makes the difference. Our washers are designed with the characteristics and materials needed to meet the demands of your specific electrical application. Common applications for our high-quality washers include:
Whatever your magnetism requirements, working temperature, or corrosive environment, our parts are made to withstand your most powerful electrical connections.
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