Expandable structure with multiple stable states

Abstract

Expandable structure (44) with multiple stable states, wherein the expandable structure (44) comprises: an elastic substrate (46) with a textile layer; and a hinged frame mounted on the textile layer (48), wherein the articulated frame (48) and the textile layer are designed to work together for the transition between: a first stable state in which the deployable structure (44) maintains a substantially planar shape; a second stable state in which the deployable structure (44) maintains a first multidimensional topography; and a third stable state in which the deployable structure (44) maintains a second multidimensional topography that differs from the first multidimensional topography; characterized by the fact that the articulated frame (48) includes an extended spine (50) between the first and second ribs (52, 54).

Description

INTRODUCTION

[0001] The present invention relates generally to mechanical structures with multiple stable states. In particular, the invention relates to an deployable structure according to the preamble of claim 1 with multiple stable states, as is known essentially from US 2004 / 0 130 182 A1.

[0002] Further details of the state of the art can be found in DE 10 2017 110 452 A1.

[0003] Modern motor vehicles, such as the contemporary automobile, are originally equipped with various assemblies and components consisting of elements made from textile materials, polymer materials, and metallic materials. A vehicle seat assembly, for example, consists of a generally upright seat back and a generally horizontal seat surface, both functionally supported on a seat platform attached to the vehicle body. Standard seat back and seat sections include a rigid metallic or polymer frame with optional spring-based suspension, an expandable foam cushion supported on the frame, and a leather or textile trim material covering the frame and cushion.Other vehicle components and assemblies that can be manufactured with textile features include, but are not limited to, interior trim, floor coverings and mats, knee pads, roof reinforcement plates, center console consoles, center consoles for armrests, instrument panel trim, trunk covers, etc.

[0004] Some vehicle components, such as the aforementioned trim panels, instrument panel covers, roof panels, and trunk lids, etc., can be manufactured as multi-layered laminate structures formed from a variety of bonded material layers. A single material layer can be selected to provide wear resistance, flexibility, compressibility, stiffness, or aesthetic functionality.

[0005] Vehicle interior trim panels, which define many of the interior surfaces within an automobile's passenger compartment, generally consist of a rigid polymer substrate attached to a door assembly frame, roof frame, or dashboard base. A flexible textile "skin" adheres to the substrate to create an aesthetically pleasing appearance and a tactilely appealing contact surface. While many of these individual layers are molded as an essentially flat blank prior to assembly, the resulting product often requires a multi-dimensional form. However, any increase in the packaging volume for a component entails a concurrent increase in the packaging and shipping costs associated with that component. SUMMARY

[0006] According to the invention, an deployable structure with several stable states is presented, characterized by the features of claim 1.

[0007] This document discloses deployable structures with multiple stable states using a bracing frame mounted on a textile substrate. As an example, a knitted textile structure (colloquially referred to as a "knit") with additional reinforcement features for multi-stable-state functionality is presented. Additive manufacturing—more commonly known as "3D printing"—can be used to print "skeletal details" onto one or more faces of a knitted support substrate. Optionally, a compliant, skeletal framework can be laminated or bonded to a prestressed textile substrate to provide articulated features and selective deployability (e.g., using appropriate origami or kigogami techniques).A component manufactured in this way can create a multi-stable-state structure that is essentially or completely planar (flat and thin) in at least one stable state, thus providing a small packaging volume for transportation and distribution. When the component is ready for assembly, it can selectively expand into another stable state to provide a predetermined space-filling volume (e.g., an operational state for structural use) to simplify installation and assembly.

[0008] For each of the disclosed systems, methods, and devices, the articulated frame can include a network of relatively rigid features or elements. These relatively rigid features or elements can be connected to one another by more flexible elements or bends that act as hinges. Likewise, the textile can be knitted or woven to possess local features that perform the same function. The elastic textile-based substrate can be locally and unevenly prestressed before the relatively stiff frame of connections is assembled to prestress selected sections or the entire structure.The frame can be further specified such that the dimensions and stiffness of these elements, features within the fabric, and elasticity of the attached substrate determine the available motion paths of the structure when it reaches initial equilibrium after tool release, as well as the available deformation types or motion paths when it is externally loaded. These parameters can be specified so that the available motion paths exhibit states in which its internal energy is relatively low / locally minimized and it becomes stable. The structure can be designed to exhibit a variety of these stable states across all or some of its available motion paths.

[0009] Aspects of this invention are directed to components and assemblies that are wholly or partially formed from a deployable structure with multiple stable state features. For example, a deployable structure with multiple stable states is presented, comprising a compliant, elastic substrate with a textile (knitted) layer and an articulated (polymeric) frame mounted on the textile layer. The articulated frame and the textile layer are designed to interact to facilitate the transition between: a first stable (or semi-stable) state in which the deployable structure maintains a substantially planar shape; a second stable state in which the deployable structure maintains a first multidimensional topography; and a third stable state in which the deployable structure maintains a second multidimensional topography that differs from the first multidimensional topography.The first multidimensional topography can be characterized by a first cross-sectional geometry, while the second multidimensional topography can be characterized by a second cross-sectional geometry that differs from the first cross-sectional geometry.

[0010] For each of the aspects and features described herein, the articulated frame according to the invention includes an elongated spine sandwiched between a first set of ribs and a second set of ribs. Each of the first ribs may project from a first lateral side of the elongated spine at a first oblique angle, while each second rib may project from a second lateral side of the elongated spine at a second oblique angle. The first oblique angle may be approximately equal to the second oblique angle or alternatively differ from it. The first plurality of ribs may be physically attached to the elongated spine by a first set or sets of hinges, while the second plurality of ribs may be physically attached to the elongated spine by a second set or sets of hinges.

[0011] For each of the aspects and features described herein, the first and second sets of ribs may be spaced apart from the extended spine when the deployable structure is in the first stable state, and conversely, may be in contact with the extended spine when the deployable structure is in the third stable state. The spine may include first and second sets of grooves configured to receive the rib ends of the first and second sets of ribs when the deployable structure is in the third stable state. The spine may be configured to change along an arc-shaped path when the deployable structure changes between the first and second stable states; the spine may be configured to change along a linear path when the deployable structures change between the second and third stable states.For at least some embodiments, adjacent segments of the elastic substrate can be folded over one another when the deployable structure is in the first stable state; these adjacent segments can be configured to unfold when the deployable structure transitions into the second and / or third stable states.

[0012] For each of the aspects and features described herein, the articulated frame may include a generally rigid frame that partially or completely surrounds the spine and ribs. For example, the textile layer of the elastic substrate includes an outer circumference; the frame may extend continuously along the outer circumference of the textile layer, surrounding the elongated spine and ribs. The ribs may be spaced from the frame when the deployable structure is in the first stable state and, conversely, may be in contact with the frame when the deployable structure is in the third stable state. The frame may include notches designed to receive rib ends when the deployable structure is in the third stable state. The frame may serve to hold the textile layer in a pre-tensioned state when the deployable structure is in at least the first stable state.

[0013] Additional aspects relate to methods for manufacturing and methods for using deployable structures with multiple stable states. For example, a method for assembling a deployable structure with multiple stable states is presented. The representative method includes, in any order and in any combination with any of the features and options disclosed above and below: receiving a compliant, elastic substrate made with a (knitted) textile layer; and attaching an articulated (polymeric) frame to the textile layer.The articulated frame and the textile layer interact structurally to transition from a first stable state, in which the deployable structure maintains an essentially planar shape, to a second stable state, in which the deployable structure maintains a first multidimensional topography, and from the second stable state to a third stable state, in which the deployable structure maintains a second multidimensional topography that differs from the first. The frame can be mounted onto the textile layer using a suitable manufacturing process, including printing, laminating, bonding, deposition, and / or curing.

[0014] Further aspects relate to vehicle components and motor vehicles equipped with all such vehicle components exhibiting multiple stable state features provided by a polymer exoskeleton attached to a textile-based, compliant, and elastic substrate. A "motor vehicle," as used herein, can include any relevant vehicle platform, such as passenger cars (internal combustion engines, electric hybrid engines, fully electric, fuel cell, fuel cell hybrid, fully or partially autonomous, etc.), transport vehicles, industrial vehicles, tracked vehicles, all-terrain vehicles (ATVs), agricultural equipment, watercraft, aircraft, etc. It is intended that each of the disclosed multi-stable-state deployable structures can be used for both automotive and non-automotive applications.

[0015] The foregoing summary is not intended to represent every embodiment or aspect of the present invention. Rather, it merely presents, by way of example, some of the novel concepts and features set forth herein. The features and advantages listed above, as well as other features and advantages, will be readily apparent from the following detailed description of the illustrated embodiments and ways of carrying out the invention in conjunction with the accompanying drawings and the appended claims. Furthermore, the present invention expressly includes all combinations and partial combinations of the foregoing elements and features described above and below. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a forward-facing perspective view of a part of a representative vehicle passenger compartment, representing various vehicle components that can be made wholly or partially from a deployable textile structure with several stable state features according to the aspects of the present invention. Fig. Figure 2 is a perspective representation of a representative deployable textile structure with several stable states, shown in a first stable state according to the aspects of the present invention. Fig. Figure 3 is a perspective view of the representative unfoldable textile structure of Fig. 2, which transitions from the first stable state to a second stable state. Fig. 3A is a cross-sectional representation of the unfoldable textile structure of Fig. 3 along line 3A-3A. Fig. 4 is a perspective view of the representative unfoldable textile structure of Fig. 3, which transitions from the second stable state to a third stable state. Fig. 4A is a cross-sectional representation of the unfoldable textile structure of Fig. 4 along line 4A-4A.

[0016] The present invention is amenable to various modifications and alternative forms of application, and some representative embodiments are illustrated by way of example in the drawings and described in detail herein. It is understood, however, that the novel aspects of this invention are not limited to the particular forms shown in the drawings above. DETAILED DESCRIPTION

[0017] With reference to the drawings, where the same reference numerals refer to the same features in the different views, Fig. 1. A perspective view of a representative automobile, generally designated 10, shown herein for the purpose of discussing a passenger car of the SUV type. Attached to the vehicle body 12 of the automobile 10, e.g., to a roof rail, a chassis crossmember, a front panel, a rear deck, etc., within a passenger compartment 14, is an assortment of representative vehicle components, which can be made wholly or partially from a deployable textile structure with several stable state features. The automobile 10 shown—also referred to herein as the “motor vehicle” or “vehicle”—is merely an exemplary application with which the novel aspects and features of this invention can be put into practice. Similarly, the implementation of the present concepts in the Fig. The vehicle components shown in Figure 1 may also be considered an exemplary application of the novel concepts disclosed herein. Accordingly, it is understood that the aspects and features of the present invention can be applied to other vehicle components that can be used for any logically relevant type of vehicle, both for automotive applications and for applications outside this field. Finally, the drawings shown herein are not necessarily to scale and are for guidance only. Thus, the specific and relative dimensions of the drawings are not considered limiting.

[0018] According to the illustrated example, a front windshield 18 is sealed to the front window frame 16, for example, by means of a bonding agent and a window seal or a polymeric sealing layer (not shown). A lower edge of the front window frame 16 is bounded by an instrument panel trim 20, while an upper edge is bounded by a roof reinforcement plate 22 and the two side edges by a pair of A-pillar trim covers 24 (only one of which is visible; a second, mirrored counterpart is located on the opposite side of the window frame 16). A center console 26 is also present within the vehicle interior 14, which is equipped, among other things, with a touchscreen video display 28 and a keypad 30. The touchscreen video display 28 and the keypad 30 can be operated independently to receive user input, while the video display 28 outputs images, text, and video-based content.A digital instrument panel (IP) 32, housed in a front dashboard 34 in front of a steering wheel 36, displays gauges, instruments, and controls for monitoring and regulating selected operations of the vehicle 10. A driver-side door assembly 38 is pivotally mounted, for example, via a multi-stage door spring hinge on the vehicle body 12, to provide access to a section of the passenger compartment 14 and to close it securely. A handle housing 42 is mounted along an inward-facing (inner) surface of an interior door panel 40, providing a lower support for the operation of the door handle 43.

[0019] Many of the vehicle components described above, including the instrument panel trim 20, the roof reinforcement plate 22, the pillar trim covers 24, the center console trim parts 26 and the instrument panel 34, and the door interior trim 40, can be manufactured from a textile arrangement designed to maintain multiple stable states. An example of a multi-stable, deployable textile structure is shown in the Fig. Figures 2-4, which are generally referred to as 44, are shown. The term "textile," as used herein, may refer to any fabric or cloth formed from natural or synthetic fibers by knitting, weaving, crocheting, braiding, binding, lacing, or any other suitable textile manufacturing process. A textile material may consist of one or more organic fibers, such as animal and plant fibers; one or more synthetic fibers, such as polymer-based or glass-based fibers; and / or one or more metal-based fibers, such as silver, gold, or aluminum filaments and aluminum materials.Textile materials produced using a combination of these processes and / or materials could have sections of the textile material containing multiple structures, for example: a knitted section formed using braided fibers; fibers woven through a knitted or crocheted structure, e.g., to provide dimensional strength and / or stabilization; a crocheted edge formed on a knitted or woven structure; layers of fabric worked together to create a multi-layered textile material such as a 3D textile material, etc.Some textile materials contain more than one type of fiber, including one or more organic fibers, synthetic fibers and metal-based fibers, as well as a mixed fiber, such as an animal / synthetic blend, an animal / plant blend, a plant / synthetic blend, a glass / polymer blend (fiberglass), a metal / polymer blend, etc., and any combination thereof.

[0020] Natural fibers are fibers produced by or from plants, animals, and geological processes. Animal fibers can include fibers made from the hair and / or fur of animals that provide suitable fiber material, as well as silk fibers, which are made from insect cocoons and the like. In contrast, plant-based fibers can include fibers made from any plant that provides suitable fiber material, including, as a non-restrictive example, cotton, flax, wood (acetate, rayon), bamboo, jute, hemp, etc. Synthetic fibers, on the other hand, are generally made from synthesized polymers and can include fibers made from one or more of the following: acrylic, KEVLAR®, nylon, Nomex, polyester, spandex, and the like.Synthetic fibers, as a non-restrictive example, can be formed by spinning, extrusion, drawing, and the like. A textile material can be formed from a yarn comprising a variety of fibers that have been spun, twisted, or otherwise bonded together to form a yarn. The textile material may include monofilament fiber, polyfilament fiber, staple fiber, or a combination thereof.

[0021] With reference to Fig. 2 The deployable textile structure 44 (hereinafter also referred to as the “deployable structure”) is depicted as a two-part, two-material construction, generally consisting of an elastic and compliant textile substrate 46 with an articulated frame 48 mounted on at least one principal surface of the substrate 46. According to the Fig. In the representative architecture shown in Figures 2-4, the flexible textile substrate 46 (hereinafter also referred to as "textile substrate" or simply "substrate") can generally consist of an essentially flat, one-piece knitted layer. Optionally, the textile substrate 46 can be designed as a multidimensional and / or multilayered material that can assume any desired shape and size for an intended application. Textile substrate 46 of Fig. 2 can be formed using a single technique or a combination of techniques. For example, the textile substrate 46 can be a knitted 3D material into which weft and / or warp threads are woven to provide directional properties such as directional elongation, pretension, predetermined deformation of spacings in the textile structure under load, damping properties, etc. In multilayer constructions, the textile substrate 46 can include interconnected layers formed by a single technique, such as a double-layer fabric composition, or at least one of several layers formed by a different technique than at least one of the other layers.It is intended that the textile substrate 46 can be formed by weaving, knitting, crocheting, braiding and the like, such that the fibers are spaced apart from each other and can move relative to each other, for example under load, so that the distance between the fibers and the orientation of one fiber to another changes in dimension, shape and orientation in response to a change in direction and size or load imposed on the textile substrate 46.

[0022] Continuing the example above, the textile substrate 46 can be described as elastic, extensible, porous, and flexible, and may optionally be capable of providing a desired response, including one or more stiffness responses, energy dissipation responses, strain displacement responses, and thermal responses. The textile substrate 46 can be manufactured with a hydrophobic, hydrophilic, wicking, or porous configuration, provided, for example, by a predetermined spacing between the fibers forming the textile, to provide fluid flow (heat, air, and vapor, including water vapor) in and / or through the textile material. The velocity and capacity of the fluid flow and the diffusion capacity of the textile material can change when an applied load is varied.The reaction properties of the textile substrate 46 can be varied by changing a stitch type, stitch pattern, yarn type, yarn denier, needle size, fiber type, fiber size, seam density, warp pattern, weave pattern, fiber pattern, braid pattern, etc., of the textile material. These characteristics of the textile material can help determine the properties of the textile substrate 46, including the density, thickness, porosity, conductivity, elasticity, etc., of the textile material, as well as the shape, size, orientation, and dynamic response of the spaces defined between the fibers in the textile material.

[0023] With further reference to the Fig. 2-4 The articulated frame 48 can be made of a polymer material, such as a laminated or printed polymer, or a metallic material, such as a plated or deposited metal. Materials that can be used to form the frame 48 include steel, aluminum, nickel, copper, gold and alloys thereof, as well as polycarbonates, polypropylene, polyester, polyethylene terephthalate (PET), polyvinyl chloride (PVC), or combinations thereof. In a first non-restrictive example, vacuum deposition, ion plating, or electroless / electrostatic plating of aluminum or nickel can be implemented to create the articulated frame 48 on a top main surface of the textile substrate 46.According to a second non-limiting example, 3D printing or laminating of aromatic or aliphatic polyether or polyester polyurethanes can be implemented to create the articulated frame 48 on a top main surface of the textile substrate 46. To improve adhesion or cohesion, the interface of the textile substrate 46 can, for example, be coated with a binder such as polyurethane binder, polyacrylate binder, or styrene-butadiene latex. Although shown as being applied only to one side / surface of the textile substrate 46, it is clearly within the scope of this invention to integrate the articulated frame 48 or to select features of the frame 48 on multiple sides / surfaces of the textile substrate 46.

[0024] According to the representative architecture of Fig. 2 The articulated frame 48 is formed with an extended, substantially straight spine 50, sandwiched or otherwise sandwiched between a first rib 52 or a first row / multiple of ribs 52A and a second rib 54 or a second row / multiple of ribs 54A. As shown, the first multiplicity of ribs 52A is on a first lateral side of the extended spine 50 (a left side in Fig. 2) arranged, the individual ribs 52 generally being aligned parallel to and spaced apart from one another along the length of the vertebral column 50. In the same way, the second plurality of ribs 54A is arranged on a second lateral side of the elongated vertebral column 50 (a right side in Fig. 2), wherein the individual ribs 54 are generally aligned parallel to and spaced apart from one another along the length of the vertebral column 50. In a stable state, which is in Fig. As shown in Figure 2, each of the first ribs 52 projects from a first lateral side of the elongated vertebral column 50 at a first oblique angle A1, while each second rib 54 projects from a second lateral side of the elongated vertebral column 50 at a second oblique angle A2. Although not required, the first oblique angle A1 may be approximately equal to the second oblique angle A2. Alternative applications may require that the oblique angles A1, A2 be different from each other, or, if desired, that one or more of the ribs 52, 54 assume a pronounced projection angle with respect to the vertebral column 50. It should be noted that the number, orientation, shape, and position of the ribs 52, 54 may differ from those shown in the drawings. For example, it is intended that each row of ribs 52A, 54A may contain more or fewer than six ribs.Furthermore, although depicted as parallelograms with beveled distal ends, ribs 52 and 54 may assume other shapes and features to achieve the revealed functionality.

[0025] The articulated frame 48 from Fig. 2 is also provided with a rigid frame 56 that partially or completely surrounds the elongated spine 50 and the two rows of ribs 52A, 54A. As shown, the frame 56 is an oval-shaped, elongated structure that extends substantially continuously along an outer circumference of the textile substrate 46 and surrounds the elongated spine 50 and the ribs 52, 54. As a continuous structure, the frame 56 can serve to hold the knitted textile layer of the substrate 46 in a pre-tensioned state, e.g., when the deployable structure 44 is in the Fig. 2 is in the stable state shown. Each rib 52, 54 in the first and second row of ribs 52A, 54A can be mechanically connected directly to the frame 56 and the elongated vertebral column 50, e.g., by a corresponding pair of bendable hinges. This is illustrated as an example. Fig. 2 an integrally formed internal hinge 58A, which is arranged between the rib 52 and the vertebral column 50, and an integrally formed external hinge 58B, which is arranged between the rib 52 and the frame 56 and connects them. As an example, illustrated Fig. 3. An integral internal hinge 60A is arranged between rib 54 and spine 50, and an integral external hinge 60B is arranged between rib 54 and frame 56, connecting them. With this architecture, the articulated frame 48—spine 50, ribs 52, 54, frame 56, and hinges 58A-B, 60A-B—can be formed as a single, unified structure. Alternatively, one or more, or all, ribs 52, 54 can be spaced apart and have no direct mechanical connection to spine 50 and / or frame 56. Similar to spine 50 and ribs 52, 54, the shape, size, and / or orientation of frame 56 can be scaled to a specific application or adapted for desired functionality.

[0026] The unfoldable textile structure 44 from the Fig. 2-4 is designed to maintain at least two, or for some configurations three or more, stable states, for example, to provide more efficient, agile manufacturing, shipping, and assembly of one of the vehicle components discussed above. In mechanical engineering, a transition state can be defined as the dynamic response of a mechanical system to an applied force that causes a change from one stable equilibrium to another. As used here, the term "stable state" can be defined as a stationary state of a dynamic mechanical system that the system can maintain without the application of an external force or energy source. In this respect, the deployable textile structure 44 is structurally configured to accommodate each of the conditions described in the Fig. 2, Fig. 3 and Fig. 4 illustrated stable states to be maintained without the need for a continued application of an external force.

[0027] According to the representative architecture illustrated in the drawings, the flexible textile substrate 46 and the articulated frame 48 are configured to interact in order to switch between three stable states: one in Fig. 2 depicted first stable (or semi-stable) state; One in Fig. 3 shown second stable state; and one in Fig. 4. The third stable state is shown. In the first stable state, which is best described in Fig. As can be seen in Figure 2, the deployable structure 44 maintains an essentially flat and planar shape, for example, for easier stacking, packaging, and shipping. Without the application of an external stimulus, the flexible textile substrate 46 and the articulated frame 48 hold the deployable textile structure 44 in this state for a continuous, if not indefinite, period of time. In contrast, a manual or automated external force F1 (e.g., a clockwise rotational force) can cause the structure to deform. Fig. 3) applied to the elongated spine 50 to unfold the textile structure 44 from the first stable state of Fig. 2 to transform into the second stable state, which is in the Fig. 3 and Fig. 3A is shown. The elastic nature of the textile substrate 46, which attempts to return the elongated spine 50 to its original position (e.g., counterclockwise in Fig. 3) to pull, is counterbalanced or otherwise offset by the angled orientation of the ribs 52, 54 in relation to the spine 50 and the frame 56. The flexible textile substrate 46 and the articulated frame 48 hold the deployable textile structure 44 in this second stationary state for a continuous, if not indefinite, time until another stimulus is applied. In the second stable state, the deployable structure 44 retains a first multidimensional topography, which in Fig. 3A is represented by the width, height and / or arc length of the first protruding curve 62.

[0028] A second manual or automated external force F2 (e.g., a generally linear force in a downward and leftward direction) Fig. 3) can be applied to the elongated spine 50 to unfold the textile structure 44 from the second stable state of Fig. to transition to the third stable state, which is best described in the Fig. 4 and Fig. 4A can be seen. Again, the elastic nature of the textile substrate 46 attempts to return the elongated spine 50 to its original position. Fig. 2 to pull back to the original position shown. However, this return movement is prevented by the ribs 52, 54 being wedged and / or compressed between the spine 50 and the frame 56, as described in more detail below. In the third stable state, the deployable structure 44 retains a second multidimensional topography, which is defined here by the width, height and / or arc length of a second in Fig. The preceding bulge 64 shown in Figure 4A is illustrated. By comparing the Fig. 3A and Fig. 4A shows that the height and arc length, and thus the topography, of the first projecting bulge 62 differs from the height and arc length, and thus the topography, of the second projecting bulge 64. In fact, the first multidimensional topography 62 has a first cross-sectional geometry ( Fig. 3A), which differs from a second cross-sectional geometry ( Fig. 4A) of the second multidimensional topography 64 differs.

[0029] With collective reference to the Fig. 2 and Fig. The first and second sets of ribs 52A, 54A are spaced apart from the elongated spine 50 and the frame 56 when the deployable structure 44 is in the first and second stable states. This spaced relationship between ribs 52, 54 and spine / frame 50, 56 can be maintained wholly or partially via the flexible textile substrate 46 in conjunction with the bending hinges 58, 60. However, the application of the second force F2 to the spine 50 rotates and collapses the hinges 58, 60 and simultaneously pushes the opposite distal ends of each rib 52, 54 against the elongated spine 50 and the frame 56. The abutting relationship between spine 50, ribs 52, 54, and frame 56 helps to hold the deployable structure 44 in the third stable state. For at least some optional configurations, the elongated spine 50 can be manufactured with first and second sets of grooves 66A and 66B respectively ( Fig. 3A); Each groove 66A, 66B is configured to receive a first (upper) rib end of a rib 52, 54 when the deployable structure 44 is in the third stable state ( Fig. 4). Likewise, the frame 56 may optionally include first and second sets of notches 68A and 68B ( Fig. 3A); Each notch 68A, 68B is configured to accommodate a second (lower) rib end of a rib 52, 54 when the deployable structure 44 transitions into the third stable state.

[0030] The representative deployable structure 44 of the Fig. 2-4 is represented as transitioning along a generally arc-shaped path when moving from the first stable state ( Fig. 2) into the second stable state ( Fig. 3) moves and then transitions along a generally linear path from the second stable state ( Fig. 3) into the third stable state ( Fig. 4) The deployable structure 44 can follow alternative paths when switching between one of the stable states described herein without deviating from the scope and purpose of this invention. For example, a first segment of the flexible textile substrate 46 (e.g., the left half in Fig. 2) and all segments of the articulated frame 48 mounted thereon onto a second segment of the flexible textile substrate 46 (e.g. the right half in Fig. 2) can be folded when the unfoldable structure 44 is in the first stable state. These two segments of the flexible textile substrate 46 can be configured so that they can be unfolded when the unfoldable structure 44 transitions into the second and / or third stable state.

[0031] In at least some embodiments, the flexible textile substrate 46 comprises a yarn having a glass transition temperature and / or a polymer melting point higher than the melting temperature of a polymer material used to manufacture the articulated frame 48. For natural fibers, it may be desirable for a peak temperature and / or a whistle point temperature of the natural fiber to be approximately equal to the melting temperature of the frame material. In at least some embodiments, bonding by adhesive bonding, fiber infiltration into the yarn structure, and / or yarn encapsulation can be used to join the frame 48 to the substrate 46.As another possible option, each loop of the flexible textile substrate 46 can be knitted with several yarns, at least one of which has a flash point / whistle point temperature above the processing temperature of the frame 48, and at least one of which has a flash point / whistle point temperature below the processing temperature of the frame 48. In this process, at least some of the fiber material melts or softens, potentially improving its adhesion to the skeletal frame (e.g., using a "melt yarn"). For the skeletal frame 48, it may be desirable to use a thermoplastic polymer; however, if adhesives or epoxies are used, most metallic, thermosetting plastics, composite materials, etc., can be used for the frame 48.

Claims

[1] A deployable structure (44) having multiple stable states, the deployable structure (44) comprising: an elastic substrate (46) with a textile layer; and an articulated frame (48) mounted on the textile layer, wherein the articulated frame (48) and the textile layer are cooperatively configured to transition between: a first stable state in which the deployable structure (44) maintains a substantially planar shape; a second stable state in which the deployable structure (44) maintains a first multi-dimensional topography; and a third stable state in which the deployable structure (44) maintains a second multi-dimensional topography that is different from the first multi-dimensional topography; characterized by , that the articulated frame (48) includes an elongated spine (50) between first and second ribs (52, 54). [2] The deployable structure (44) of claim 1, wherein each of the first ribs (52) projects from a first lateral side of the elongated spine (50) at a first oblique angle, and each of the second ribs (54) projects from a second lateral side of the elongated spine (50) at a second oblique angle. [3] The deployable structure (44) of claim 2, wherein the first oblique angle is approximately equal to the second oblique angle. [4] The deployable structure (44) of claim 1, wherein the first ribs (52) are physically attached to the elongate spine (50) by a first set or sets of flexure hinges (58), and the second ribs (54) are physically attached to the elongate spine (50) by a second set or sets of flexure hinges (60). [5] The deployable structure (44) of claim 1, wherein the first and second ribs (52, 54) are spaced from the elongated spine (50) when the deployable structure (44) is in the first stable condition and conversely abut the elongated spine (50) when the deployable structure (44) is in the third stable condition. [6] The deployable structure (44) of claim 5, wherein the spine (50) includes first and second sets of grooves (66A, 66B) configured to receive the rib ends of the first and second ribs (52, 54) therein when the deployable structure (44) is in the third stable condition. [7] The deployable structure (44) of claim 1, wherein the articulated frame (48) further at least partially surrounds the elongated spine (50) and the first and second ribs (52, 54). [8] The deployable structure (44) of claim 7, wherein the fabric layer includes an outer perimeter, and wherein the frame (48) extends continuously along the outer perimeter of the fabric layer and surrounds the elongated spine (50) and the first and second ribs (52, 54).

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