Folding mechanics of a bistable composite tape-spring for flexible mechanical hinge

Abstract

A bistable composite tape-spring (CTS) structure is stable in both extended and coiled configurations, which can be fully coiled or folded. Its bistable coiling feature has been employed in a Roll-Out Solar Array and successfully deployed in space; its foldable characteristics is analogous to a flexible mechanical hinge, showing great potential to be applied in an aircraft landing gear. Both the structural coiling and folding mechanics are dependent on tape geometry; whilst the correlated scale effect has not been investigated, which significantly constrains its foldable mechanical hinge designs and smart driving analysis in order to further reduce weight and complexity for conventional mechanical hinges. Here, we studied the folding stability mechanics of the CTS structure towards its full tape-length range, where novel stress and shape transitional mechanisms are revealed. This is achieved by investigating the quasi-static folding process of the CTS, where new stable shape features in terms of critical transitional length and stable folded angle are observed and identified through experimental observations, finite element model, as well as theoretical analysis. Theoretical criteria were then determined from the strain energy analysis in comparison to the predefined folded tape shape features. The folding stability mechanisms towards its full tape-length range were proposed in order to facilitate customized flexible hinge design and in-situ smart driving analysis in order to replace conventional mechanical hinges.