Continuous Artificial Muscle Fiber Twisting via Localized Heating
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Solution Overview
Problem
Conventional methods for producing twisted artificial muscle fibers are batch-to-batch processes, limiting the production of large quantities and often result in snarls due to uneven twist distribution, which can lead to fiber breakage or improper twist application.
Innovation Solution
A continuous manufacturing method and apparatus that involves threading an untwisted fiber through a tube with localized heating sections to soften and twist the fiber, controlling tension to prevent snarling, and varying the tube's diameter to allow for both twisting and coiling without fiber breakage, enabling the production of twisted or coiled fibers with a higher bias angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-to-batch production methods are used for twisted artificial muscle fibers, then production flexibility is maintained, but production quantity and efficiency are limited
Solution Approach 1:
The patent implements a continuous production system where fibers are twisted and coiled continuously through a tube rather than in discrete batch operations. The fiber feedstock is fed continuously through the heating zone and twisting mechanism, enabling large-scale production while maintaining process control through consistent parameters throughout the continuous operation.
2Manufacturing precision
If high twist is applied to the fiber to achieve desired actuation properties, then bias angle is improved, but snarls and fiber breakage occur due to uneven twist distribution
Solution Approach 1:
The patent utilizes temperature as a critical parameter to change the fiber's mechanical properties during processing. By heating the fiber to its melting point or below, the fiber becomes more pliable and easier to twist without breaking. The temperature is carefully controlled to achieve the desired bias angle while preventing fiber damage, and then cooled to lock in the twisted structure.
Solution Approach 2:
The fiber is pre-heated to its melting point or below before twisting is applied. This preliminary thermal treatment softens the fiber, making it more susceptible to twisting and reducing the risk of breakage during the twisting process. The fiber is then cooled after twisting to set the desired configuration.
3Ease of manufacture
If localized heating is applied to soften the fiber for twisting, then twist application is improved, but temperature control precision is required to prevent fiber damage
Solution Approach 1:
The patent applies localized heating to specific zones along the fiber where twisting is required, rather than heating the entire fiber uniformly. This allows precise control of the thermal softening process at the twisting location while keeping other portions of the fiber at ambient temperature, reducing the risk of overheating and simplifying temperature control requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient and reliable production of twisted or coiled artificial muscle fibers with a higher bias angle, reducing the risk of snarling and fiber breakage, and facilitating the widespread commercial use of artificial muscles by allowing for continuous large-scale production.
Implementation Method 1
The tube includes a heating means to raise a localized temperature of a cross-section of the tube to a predetermined temperature
Data Source
AI summary
Methods and a device for the continuous manufacturing of artificial muscle actuator device fibers are disclosed. The method includes: threading an untwisted fiber along the axis of a tube and inside the tube that includes a heating means to raise the localized temperature of a cross-section of the tube to a predetermined temperature; providing a tension on the untwisted fiber; and twisting the untwisted fiber while the fiber is within the tube.