Interlocking Strip Tube Linear Actuator for Compact Spooling
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Solution Overview
Problem
Existing mechanical linear actuators face limitations in structural efficiency due to thickness constraints and backlash issues, particularly in compact designs that require a wide range of column diameters, which affect their strength-to-weight ratio and scalability.
Innovation Solution
A reversible method for constructing a multi-ply wall tube using flexible strips with a constant inside and outside diameter, where the strips interlock without a separate locking member, allowing for high strength, scalability, and easy assembly/disassembly, using an assembler/disassembler to transition between stored and deployed states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the strip thickness is increased to withstand acute load forces and avoid plastic deformation, then the structural strength is improved, but the spool diameter increases and the strip cannot be spooled in a tighter form
Solution Approach 1:
The tube is constructed from multiple separate flexible strips that are spooled independently and then interlocked during deployment. This segmentation allows each strip to be spooled in a compact form while collectively providing the required structural strength when assembled into the tubular configuration.
Solution Approach 2:
Multiple strips are nested within each other during spooling, with each strip contained within the spool assembly. When deployed, these nested strips interlock to form the tubular structure, achieving compact storage while maintaining structural integrity.
2Ease of manufacture
If tabs are used to join strip material, then the strip can be constructed, but the tab strength becomes the limiting factor for axial load transfer
Solution Approach 1:
The joining function is merged with the structural strips themselves through interlocking features that are integral to the strips. This eliminates separate tab components and creates a unified load-bearing structure where the strips collectively transfer axial loads through their interlocked configuration.
Solution Approach 2:
Multiple strips are combined into a composite tubular structure where the collective arrangement of interconnected strips provides enhanced axial load transfer capability beyond what a single strip or tab connection could achieve.
3Length of moving object
If the column base diameter constantly increases as the column extends, then the column can be constructed, but the drive mechanism must accommodate a wide range of column diameters
Solution Approach 1:
The tubular structure is constructed from flexible strips that can dynamically adjust their configuration during extension and retraction. The strips bend and flex to accommodate changing diameters, allowing the drive mechanism to operate with a more consistent interface rather than accommodating a constantly changing column diameter.
Solution Approach 2:
Flexible strips are used to construct the tubular column, allowing the structure to bend and flex during deployment and retraction. This flexibility enables the column to maintain a more consistent effective diameter at the drive interface while still achieving full extension, simplifying the drive mechanism design.
4Reliability
If separate locking members are used to lock flexible strips, then the strips can be secured, but the device complexity increases
Solution Approach 1:
The strips are designed with self-interlocking features that automatically secure the strips to each other during assembly and deployment. The interlocking geometry of the strips themselves provides the locking function without requiring separate locking members, achieving reliability while minimizing complexity.
Data Source
AI summary
The present invention relates to a linear actuator comprised of a tube and method of deploying 3 spools of strips into a tube by consolidating the strips in an overlapping condition with each other each in a helical form of a constant diameter.