Twisted Coiled Polymer Actuation for Lightweight Active Aero Modules

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Solution Overview

Problem

Current automotive-grade actuator units for active aero modules are heavy and expensive, making them costly to integrate into systems like active grill systems, necessitating a lightweight and cost-effective alternative to rotary drive functions.

Innovation Solution

A twisted coiled polymer (TCP) actuator system is used in a kinematic mechanism to provide a low-cost, lightweight actuation solution for active aero modules, utilizing TCP units as load generation, trigger-latch mechanisms, pulley systems, and simple levers to achieve linear force or torque for actuating components like AGS vanes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If DC electric motor units are used for actuation, then reliability and robustness are improved, but weight and cost increase significantly

Engineering Contradiction:

Improveactuator reliabilityVSAvoidactuator weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent replaces the DC electric motor system with a twisted coiled polymer (TCP) actuator system that uses electrothermal actuation. The TCP actuator converts electrical energy to mechanical motion through resistive heating, eliminating the need for heavy motor components, gearboxes, and control electronics while maintaining reliable actuation functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the actuation mechanism from electromagnetic (motor) to electrothermal (TCP). By applying electrical current to heat the TCP actuator, it undergoes dimensional changes that produce mechanical motion. This parameter change from electromagnetic to thermal actuation enables weight reduction while preserving reliability through controlled thermal-mechanical response.

Inventive Principle:

Principle #35Parameter changes

2Force

If DC electric motor units are used for actuation, then actuation force and torque are sufficient, but cost and system complexity increase

Engineering Contradiction:

Improveactuation forceVSAvoidactuator system complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent extracts and removes the complex control units, gearboxes, and additional mechanical components associated with DC motor systems. The TCP actuator provides direct mechanical motion without requiring these intermediate components, simplifying the overall actuator system while maintaining sufficient actuation force through the polymer's inherent mechanical properties.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The TCP actuator is self-contained and self-actuating. When electrical current is applied, the polymer automatically converts thermal energy to mechanical motion without requiring external control systems, sensors, or complex mechanical transmissions. This self-service capability reduces system complexity while delivering the necessary actuation force.

Inventive Principle:

Principle #25Self-service

3Weight of moving object

If TCP actuators are used, then weight and cost are reduced, but integration into existing systems requires new approaches

Engineering Contradiction:

Improveactuator weightVSAvoidsystem integration ease

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent segments the actuation system into modular TCP actuator units that can be independently integrated into active aero modules. This segmentation allows for standardized, lightweight TCP components to replace bulky motor assemblies, facilitating easier manufacturing and integration while reducing overall system weight.

Inventive Principle:

Principle #1Segmentation

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

The TCP actuator system effectively replaces heavy DC electric motors with a lightweight, cost-effective solution that can efficiently actuate active aero modules, offering a robust and affordable alternative for automotive applications.

Implementation Method 1

twisted coiled polymer (TCP) actuator system is used in a kinematic mechanism to provide a low-cost, lightweight actuation solution

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

Each cycle of our concept TCA (twisted coil actuator) kinematic mechanism outputs a linear force-load or torque capable of being used to actuate an active aero module

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20240336129A1Twisted coiled actuator kinematic system for automotive aero devices

Publication Date: 2024.10.10 MAGNA EXTERIORS INC

AI summary

An active air module for a vehicle. The module includes an active air feature having at least an open and closed position. Air is allowed to enter when in the open position and airflow is at least partially blocked in the closed position. A soft actuator such as a twisted coiled polymer actuator apparatus is used for actuation of the active air feature from the closed position to the open position.