Stable shape-reconfigurable structures and mechanisms

In one embodiment, a shape-reconfigurable structure includes a rigid base having first and second ends, a rigid first beam having a lateral end and a central end, the lateral end being connected to the first end of the base, and a rigid second beam having a lateral end and a central end, the lateral end of the second beam being connected to the second end of the base and the central end of the second beam being connected to the central end of the first beam, wherein the structure can be placed in an expanded orientation in which the first and second beams extend outward away from the base and a contracted orientation in which the first and second beams extend inward toward the base.

BACKGROUND

Shape-reconfigurable materials and structures are capable of achieving significant morphological change upon application of relatively small loads and maintaining the desired shape when the loading is removed. This deformation is reversible and the original shape is recoverable by reversing the load direction. This property could pave the way for manufacturing of highly adaptable components that are fully reconfigurable based on functionality. For example, a multistable reconfigurable structure can be significantly compressed to be transported with considerably less cost before deployment, or it can be used to fabricate tools with multiple stable shapes for different purposes. Other foreseeable applications include energy and impact absorption, tunable phononic response, and vibration isolation.

Several strategies aimed at achieving these goals have been proposed, including foldable origami, tension controlled tensegrity structures, shape-memory morphing materials and structures, shape-shifting jamming materials, and modular self-assembled structures. In most of these systems, the ability of the material or structure to morph is limited in terms of allowable direction and amplitude of deformation. For instance, origami folding is often based on a single degree-of-freedom rigid folding mechanism and is an energetically inefficient strategy for multi-axial straining.

DETAILED DESCRIPTION

As identified above, current shape-reconfigurable materials and structures are limited in their ability to morph in terms of allowable direction and amplitude of deformation. Disclosed herein are shape-reconfigurable structures and mechanisms that, at least in some embodiments, exhibit greater ability to morph both in terms of direction and deformation. In some embodiments, the structures and/or mechanisms comprise one or more bistable shape-reconfigurable structures that can be placed and remain in, one of two different stable orientations, an extended orientation or a retracted orientation, until manipulated to move into the other orientation.

In some embodiments, the bistable shape-reconfigurable structures include a base and two beams that are connected to the base. The beams connect to the base and to each other with hinges (e.g., living hinges) that enable the beams to move relative to the base and each other. When the structure is in the expanded orientation, the beams are angled outward away from the base and the beams and the base together form a triangular shape. When the structure is in the contracted orientation, the beams are angled inward back toward the base so as to collapse the triangle and occupy less space. The structures are completely reversible so that they can be repeatedly placed in one stable orientation or the other, as desired. Such structures can be used as fundamental building blocks that can be combined in small or great numbers to form simple or complex multistable shape-reconfigurable structures or mechanisms that can be placed in multiple stable orientations. Such structures and mechanisms can be two or three dimensional.

In the following disclosure, various specific embodiments are described. It is to be understood that those embodiments are example implementations of the disclosed inventions and that alternative embodiments are possible. All such embodiments are intended to fall within the scope of this disclosure.

Disclosed herein is a novel concept for achieving independent multi-axial deformation with high volumetric and morphological change in two- and three-dimensional structures based on unit cells comprising bistable shape-reconfigurable structures having living hinges. Each unit cell can comprise multiple bistable shape-reconfigurable structures that enable the volumetric and morphological change.

FIGS. 1A and 1Billustrate an example of such a bistable shape-reconfigurable structure10, which can act as a fundamental building block that can be used in multiple numbers to form a great variety of multistable structures and mechanisms. As shown inFIG. 1A, the bistable shape-reconfigurable structure10generally comprises a rigid base12and two rigid beams14, which are connected to the base with lateral hinges16and connected to each other with a central hinge18. The base12itself comprises an elongated rigid member20that, in the example ofFIG. 1, has a rectangular cross-section. Because the member20is rigid, it does not bend or otherwise deform during manipulation of the structure10. The base12further comprises a spacer element22provided at and extending vertically upward from each end of the member20, when the member is assumed to be aligned along a horizontal direction. As will be apparent from the discussion that follows, the spacer elements22provide space between the base12and the beams14that enables the structure10to be placed in the contracted orientation shown inFIG. 1B. In this example, each spacer element22has a generally triangular shape with the base of the triangle being parallel to the member20and the top tip of the triangle being flattened.

Both beams14are of equal length (a length shorter than the length of the base12) and, in the embodiment ofFIG. 1, also have rectangular cross-sections. In addition, however, each end of each beam14is tapered to enable the bistable shape-reconfigurable structure10to collapse into the retracted orientation. In the example ofFIG. 1, each end of each beam14has a generally triangular tip that forms a point that extends along a longitudinal direction of the beam. Because the beams14are rigid, they also do not bend or otherwise deform during manipulation of the structure10.

In some embodiments, the bistable shape-reconfigurable structure10is unitarily formed from a single piece of material, such as a polymer, metal, or ceramic material. In such cases, the hinges16,18are flexible living hinges that are composed of the same material as the base12and the beams14and that are capable of bending and/or deforming to enable the structure10to be alternately expanded and contracted. In the illustrated embodiment, the hinges16,18each comprise a thin, elongated piece of material having a rectangular cross-section. Notably, the hinges16,18are thinner, and comprise less material, than both the base member20and the beams14. It is for this reason that the hinges16,18can bend and/or deform. In alternative embodiments, the hinges16,18can be made to have lower flexural rigidity than the beams14,20by using a relatively stiff material for the construction of the beams and relatively soft material for the hinges. This can be achieved through functional-grading or by forming the hinges16,18from different materials, thereby implementing a bi-material design. In the illustrated embodiment, the hinges16extend horizontally from the top ends of the spacer elements22of the base12to the lateral ends of the beams14and the hinge18extends horizontally between the central ends of the beams.

InFIG. 1A, the bistable shape-reconfigurable structure10is shown in a first, expanded orientation in which the beams14are angled outward (upward) away from the base12such that the structure has a generally triangular shape. In this orientation, the central ends of the beams14and the central hinge18are positioned at a maximum distance away from the base12and each beam forms an angle α with the horizontal direction (which is parallel to the base).

FIG. 1Bshows the bistable shape-reconfigurable structure10in a second, contracted orientation in which the beams14have been moved to a position in which they are angled inward (downward) toward from the base12. As is apparent fromFIG. 1B, the structure10is no longer triangle shaped while in this orientation (although it can be said that the structure has the shape of a triangle whose top has collapsed inward). The structure10can be placed in this orientation by applying a critical downward vertical force the top of the structure (e.g., at the central hinge18) so as to cause the beams to snap downward into the contracted orientation. In this orientation, the central ends of the beams14and the central hinge18are positioned at a minimum distance away from the base12and each beam forms an angle −α (or approximately −α) with the horizontal direction. Accordingly, the beams14can be moved through an angle of approximately 2α. As noted above, the base12and the beams14are rigid. As such, they do not bend or otherwise deform when the structure10is transitioned from the expanded orientation to the contracted orientation, and vice versa. Instead, it is the flexible hinges16,18that enable the structure10to transition between the two orientations.

As can be appreciated from comparison betweenFIGS. 1A and 1B, the bistable shape-reconfigurable structure10has a much smaller height while in the contracted orientation and, therefore, enables space savings while in that orientation. Notably, the structure10is stable in either orientation, meaning that the structure is will naturally remain in either orientation until a critical force is applied to the structure to transition it from its current orientation to the other orientation. Because the structure10is stable in two orientations, the structure10can be referred to as being “bistable.” As noted above, the structure10is completely reversible so that it can be repeatedly placed in one stable orientation or the other, as desired.

It is noted that, in some embodiments, the bistable shape-reconfigurable structure10can be described as having a “stepped beam” design as it comprises a rigid base12and rigid beams14connected to the other components in the structure (i.e., another beam or the base) with living hinges16,18at each end. This design significantly enhances the energy-absorption capacity and strength of the structure10, as well as other structures and mechanisms that incorporate the structure. It is further noted that, because the structure10has a triangular shape (at least in the expanded orientation), it can be easily tessellated to form more complicated two-dimensional and three-dimensional structures and mechanisms.

FIGS. 2A and 2Billustrate an alternative bistable shape-reconfigurable structure30that has a construction similar to that described above in relation toFIGS. 1A and 1B. Accordingly, the structure30also comprises a rigid base32and two rigid beams34that are connected to the base with lateral hinges36and to each other with a central hinge38, each of being a flexible living hinge when the structure is unitarily formed from a single piece of material. The base32includes an elongated member40and spacer elements42provided at and extending vertically upward from each end of the member. Each of the beams34is of equal length but is shorter than the base32. The ends of each beam34are tapered also to enable the structure30to collapse. In the embodiment ofFIG. 2, however, the structure30further includes a first lever44that extends horizontally outward from the base along its longitudinal direction and a second lever46that extends outward from one of the beams34along its longitudinal direction in a manner in which both levers generally point to the same side of the structure. For instance, in the example ofFIG. 2, the levers44,46both point to the left side of the structure30. As can be most easily appreciated fromFIG. 2A, additional material can be provided at the point at which the lever46“connects” to its beam34to provide greater structural integrity. As the lever46and its beam34are made of the same material and therefore are actually the same component, this additional material can be considered to be part of the lever, part of the beam, or both.

The bistable shape-reconfigurable structure30can be operated in similar manner to the bistable shape-reconfigurable structure10ofFIG. 1, except that the structure can be contracted from the expanded orientation shown inFIG. 2Ato the contracted orientation shown inFIG. 2Busing the levers44,46. More particularly, one or both of the levers44,46can be moved toward the other lever so as to cause the beams34to collapse inward toward the base32. As can be appreciated fromFIG. 2B, the levers44,46can be generally parallel to each other when the structure30is in the contracted orientation.

Bistable shape-reconfigurable structures of the types shown inFIGS. 1 and 2can be combined with other bistable shape-reconfigurable structures of the same or different configuration to form multistable shape-reconfigurable structures and mechanisms.FIGS. 3A and 3Bshow an example of a multistable shape-reconfigurable structure50that comprises two connected bistable shape-reconfigurable structures. More particularly, the structure50comprises a first bistable shape-reconfigurable structure52and a second bistable shape-reconfigurable structure54. Each of these bistable shape-reconfigurable structures52,54has a construction similar to the bistable shape-reconfigurable structure30ofFIG. 2, except that each omits the second lever46(seeFIG. 2). As indicated inFIG. 3, the two bistable shape-reconfigurable structures52,54are “connected” such that the beams34farthest from the levers44are connected together. In some embodiments, these two beams34, as well as the remainder of the structure50, can also be unitarily formed from a single piece of material. As can be most easily appreciated fromFIG. 3A, the portion of the structure50that forms the two “connected” beams is relatively thick to provide enough space for the adjacent ends of the structures52,54.

As shown inFIG. 3B, the bistable shape-reconfigurable structures52,54can be contracted to fully collapse the entire multistable shape-reconfigurable structure50to greatly reduce the space that the structure occupies. Notably, each of the structures52,54can be independently contracted as desired.

FIGS. 4A and 4Billustrate another example multistable shape-reconfigurable structure60. In this case, the structure60generally combines two multistable shape-reconfigurable structures50shown inFIG. 3. In the structure60, however, each of the structures50omit one of the levers44. The two structures50are connected together such that the bistable shape-reconfigurable structure54of the first structure50is connected to the bistable shape-reconfigurable structure52of the second structure50. More particularly, the base32of the bistable shape-reconfigurable structure54of the first structure50is connected to (or shared with) the base32of the bistable shape-reconfigurable structure52of the second structure50. With this configuration, the structure60comprises four bistable shape-reconfigurable structures52,54. As with the previously described multistable shape-reconfigurable structure50, the individual bistable shape-reconfigurable structures62-68of the structure60can be independently contracted as desired.FIG. 4Ashows each of the bistable shape-reconfigurable structures62-68in the expanded orientation andFIG. 4Bshows each of the bistable shape-reconfigurable structures in the contracted orientation.

FIGS. 5A and 5Billustrate a further example multistable shape-reconfigurable structure70. In this case, the structure70combines bistable shape-reconfigurable structures similar to the bistable shape-reconfigurable structure10ofFIG. 1. More particularly, as indicated inFIG. 5A, the structure70includes four bistable shape-reconfigurable structures72-78that can be independently expanded or contracted, which are demarcated by the dashed lines in the figure. Each of these structures72-78includes a base80and beams82that are connected to the base with lateral hinges84and connected to each other with central hinges86. As with the previously described embodiments, the structure70can be unitarily formed from a single piece of material, in which case the hinges82,84are living hinges. As shown inFIG. 5A, the structure70generally forms a square having square-shaped notches at each corner of the square when the structure is in the fully expanded orientation (i.e., with each bistable shape-reconfigurable structure72-78in the expanded orientation).

As is apparent inFIG. 5A, the bases80of the bistable shape-reconfigurable structures72-78are “connected” to each other. When the multistable shape-reconfigurable structure70is made from a single piece of material, each of the bases80comprises a portion of a unitary central member88having a four-pointed star shape. This results in bases80that each have a V-shaped side that faces the beams82. This V-shape provides space for the beams82when the structures72-78are in their contracted orientations shown inFIG. 5B.

In the example ofFIG. 5, the beams82of the bistable shape-reconfigurable structures72-78are quadrilaterals, comprised of an angled inner side that faces the base80, two parallel lateral sides, and an outer side that is opposite to the inner side and perpendicular to the lateral sides. As shown inFIG. 5A, the V-shapes of the bases80and the inner sides of the beams82result in diamond-shaped spaces90being formed within each structure72-78. These diamond-shaped spaces have two small angles of approximately 2α, as discussed before, and two large angles of approximately 180-2α. As shown inFIG. 5B, when the bistable shape-reconfigurable structures72-78are contracted, the inner sides of the beams82contact (or at least are positioned in close proximity to) the V-shaped sides of the bases such that the spaces90are occupied by the beams. As is apparent fromFIG. 5B, when the outer sides of beams82are angled approximately 2α with respect to the longitudinal axis of the diamond-shaped spaces90, the multistable shape-reconfigurable structure70also forms a square having square-shaped notches at each corner when the structure is in the fully contracted orientation (i.e., with each structure72-78in the contracted orientation). This square, however, is much smaller than the square formed by the structure70when in the fully expanded orientation shown inFIG. 5A. Multistable shape-reconfigurable structures of the types described above can also be used as building blocks to design multi-degree-of-freedom, multistable shape-reconfigurable structures and mechanisms.FIGS. 6A and 6Billustrate an example of a multistable shape-reconfigurable mechanism100that is constructed using four multistable shape-reconfigurable structures. As shown inFIG. 6A, the mechanism100comprises first and second medial multistable shape-reconfigurable structures102and104of the type shown inFIG. 4. Like the multistable shape-reconfigurable structure60ofFIG. 4, each multistable shape-reconfigurable structure102,104comprises four bistable shape-reconfigurable structures that can be independently expanded or contracted. Both multistable shape-reconfigurable structures102,104includes levers or arms106that extend laterally outward in similar manner to the levers44shown inFIG. 4. One arm106from each multistable shape-reconfigurable structure102,104connects to one of two end multistable shape-reconfigurable structures108and110. More particularly, each of the arms106connects to one of the beams of a bistable shape-reconfigurable structure of one of the multistable shape-reconfigurable structures108,110. Notably, the multistable shape-reconfigurable structures108,110each omit the levers44used in the multistable shape-reconfigurable structure60ofFIG. 4.FIG. 6Ashows each of the bistable shape-reconfigurable structures of the multistable shape-reconfigurable mechanism100in the expanded orientation andFIG. 4Bshows each of the bistable shape-reconfigurable structures of the multistable shape-reconfigurable mechanism in the contracted orientation.

The multistable shape-reconfigurable mechanism100ofFIG. 6can be used as a linear extension unit with significant axial deformation range. Besides axial extension, a linear extension unit has two additional kinematic degrees of freedom (i.e., lateral movement and rotation). The load-displacement cyclic response of a linear extension unit with stretch ratio of λ=1.75 is shown inFIG. 7. This unit was fabricated in polytetrafluoroethylene (PTFE) by laser cutting. This architecture displays some unique mechanical characteristics. First, there is a wide range of stretch (Δλ=1.6) for which the applied load is almost constant (˜1 N). At an extension of approximately 70 mm, the full extension is reached and the force increases dramatically thereafter. Second, the load-displacement response is non-reversible upon unloading, as is explained below, resulting in significant cyclic energy dissipation (˜70 N·mm). Third, there are multiple stability points between the minimum and maximum expanded configurations, labeled from 1 to 6, at each of which the removal of loading will result in a stable position (i.e., zero load and a positive load displacement slope). When higher values of stretch ratio are desirable, the linear extension unit can be designed to include a higher total lever length.

Multistable shape-reconfigurable mechanisms of the type described above can also be combined to form other, more complex multistable shape-reconfigurable mechanisms.FIGS. 8A and 8Bshow a multistable shape-reconfigurable mechanism120in fully expanded and fully contracted orientations, respectively. The mechanism120comprises a plurality of multistable shape-reconfigurable mechanisms122similar to the multistable shape-reconfigurable mechanism100(linear extension unit) shown inFIG. 6. As shown inFIG. 8A, the mechanisms122are configured in a periodic arrangement obtained by Cartesian tiling to form a rectangular array in which there are rows and columns of mechanisms connected to each other in series. The array includes central hubs124. In the example shown inFIG. 8, four mechanisms122extend from each hub124in four different orthogonal directions (i.e., 0°, 90°, 180°, and 270°). In the illustrated embodiment, the hubs124are square but rotated 90° relative to the rows and columns so as to appear to have diamond shapes within the array. It is noted that the mechanism100can be placed in a range of stable deformed configurations beyond the fully expanded configuration ofFIG. 8Aand the fully contracted configuration ofFIG. 8B. Specifically, through selective collapsing of individual bistable shape-reconfigurable structures and/or multistable shape-reconfigurable structures of the mechanism120, the mechanism100can, for example, be manipulated to form various shapes, such as an O-shaped, a V-shaped, or an X-shaped structure.

FIGS. 9A and 9Billustrate a further multistable shape-reconfigurable mechanism130. This mechanism130comprises multiple multistable shape-reconfigurable structures132similar to the multistable shape-reconfigurable structure70ofFIG. 5. In the example ofFIG. 9, each of these structures132is connected to at least two other structures132. In particular, the outer corners of the central ends of the beams of the structures132are connected to the outer corners of the central ends of the beams of adjacent structures132with further hinges134to form a rectangular array of rows and columns of structures connected to each other in series. Notably, the hinges134differ from the hinges84,86of the individual structures132(seeFIG. 5) as the hinges134are not snap-through hinges and simply flex during expansion and contraction of the mechanism130. Because of this, the hinges134bear different loads and their configurations (e.g., thicknesses) can be different from those of the hinges16,18.FIG. 9Ashows the mechanism130in the fully expanded orientation andFIG. 9Bshows the mechanism in the fully contracted orientation.

In some cases, the general objective for the multistable shape-reconfigurable mechanisms is to obtain a significant amount of deformation with relatively small applied loads. However, in energy absorption applications or when the shape reconfigurable structure is load-bearing, higher values of strength may be desirable. The multistable shape-reconfigurable mechanism130ofFIG. 9exhibits high-strength. The load-displacement cyclic response of a 5×5 prototype having a construction similar to the mechanism shown inFIG. 9was fabricated having a stretch ratio of λ=1.37. As shown inFIG. 10, the prototype mechanism had a significant hysteresis area and six load drops of roughly equivalent magnitudes. An estimation of the snap-through strength of the periodic material from analytical methods (discussed below) is also shown inFIG. 10.

FIGS. 11A and 11Bshow a further example of a multistable shape-reconfigurable mechanism140in fully expanded and fully contracted orientations, respectively. Like the multistable shape-reconfigurable mechanism100ofFIG. 6, the mechanism140comprises a plurality of multistable shape-reconfigurable structures142similar to the multistable shape-reconfigurable structure60ofFIG. 4. As shown inFIG. 11A, the structures142are arranged in series along four arms144of the mechanism140, which each arm extends outwardly from a central hub146in four different orthogonal directions. Each structure142is connected to the next structure in the series with a further multistable shape-reconfigurable structure148that each comprises two multistable shape-reconfigurable structures similar to the shape-reconfigurable structure60ofFIG. 4facing opposite directions and being connected by two oppositely facing bistable shape-reconfigurable structures similar to the bistable shape-reconfigurable structure10ofFIG. 1. The structures142are also arranged in parallel with each other along each arm144as each structure142has a corresponding structure142of similar construction positioned across from it along the arm. The mechanism140exhibits a relatively large stretch ratio. For example, the mechanism140can have a stretch ratio of λ=3.5.

The above-described structures and mechanisms are all two-dimensional. These structures and mechanisms can, however, be used to form three-dimensional multistable shape-reconfigurable mechanisms.FIG. 12shows an example three-dimensional multistable shape-reconfigurable mechanism150. As can be appreciated from this figure, the mechanism150comprises two orthogonally arranged multistable shape-reconfigurable mechanisms similar to the multistable shape-reconfigurable mechanism100ofFIG. 6. More particularly, the mechanism150comprises a first multistable shape-reconfigurable mechanism152that is 90° out of phase of a second multistable shape-reconfigurable mechanism154. By using two joined and aligned two-dimensional multistable shape-reconfigurable mechanisms152,154arranged in two perpendicular planes, the two additional degrees of freedom can be suppressed and a unit cell is obtained that can only stretch in the axial direction.

FIG. 13shows another three-dimensional multistable shape-reconfigurable mechanism160. As can be appreciated from this figure, the mechanism160comprises three mutually orthogonal multistable shape-reconfigurable structures similar to the multistable shape-reconfigurable structure70ofFIG. 5. More particularly, the mechanism160comprises a first structure162that is 90° out of phase of a second structure164, and a third structure166that is 90° out of phase of both the first structure162and the second structure164.

Three-dimensional multistable shape-reconfigurable mechanisms of greater complexity can be formed using repeated, smaller three-dimensional multistable shape-reconfigurable mechanisms. As an example,FIG. 14shows a three-dimensional multistable shape-reconfigurable mechanism170that comprises a plurality of three-dimensional multistable shape-reconfigurable mechanisms172similar to the three-dimensional multistable shape-reconfigurable mechanism150ofFIG. 12arranged in a three-dimensional array having multiple planes, each plane including rows and columns of mechanisms172. As a further example,FIG. 15shows a three-dimensional multistable shape-reconfigurable mechanism180that comprises a plurality of three-dimensional multistable shape-reconfigurable mechanisms182similar to the three-dimensional multistable shape-reconfigurable mechanism160ofFIG. 13arranged in a three-dimensional array having multiple planes, each plane including rows and columns of mechanisms182. A prototype of this mechanism180was fabricated having an axial contraction ratio of λ=1.4.

The ability to capture the load-displacement response of multistable structures and mechanisms with analytical or numerical models is essential for design activities. Such a response can be obtained from the mechanical behavior of its constituent bistable shape-reconfigurable structures (i.e., triangular units), such as that shown inFIG. 1. The problem of a bistable triangular unit under vertical force can, in turn, be reduced to the response of an inclined guided beam restrained between two vertical walls because the reflection symmetry of the unit is about the vertical center line and also the fact that the triangle base is relatively rigid and thus cannot bend or stretch. An analytical method was used in a study to obtain the load-displacement response of inclined guided beams with living hinges based on the beam-deflection method, which provided great insight on the underlying physics at different stages of response of the bistable element with non-convex elastic energy. The analytical method divided the overall deflection and axial shrinkage of the beam into three deflection modes, namely axial stretching, symmetric bending, and asymmetric bending.

Analysis has revealed that the load-displacement response of a uniform inclined guided beam follows five consecutive stages, as shown in16A. In the first stage, the beam is subjected to purely axial compression due to the stretching dominated static and a kinematic response of the structure under small deformations. This behavior is nearly linear. In general, this stage is abruptly ended at the critical load of 4π2sin α, where the structure suddenly buckles into the well-known problem of a column with two fixed ends under axial compression. During this second stage, the load-displacement response has a negative slope (spinodal phase) and the deformation is almost purely symmetric. In stage three, the deformation is a combination of symmetric and asymmetric components and the slope is negative (cont. spinodal phase). In stage four, the symmetric component of deformation disappears, and the response takes a positive slope again. Finally in stage five, the behavior becomes purely stretching dominated. If the thickness to length ratio of the hinges is sufficiently large, the symmetric buckling strength of the inclined beams is higher than the maximum axial load induced in the beams during the snap-through and no bifurcation in the load-displacement response is observed. In this case, the load-displacement response comprises only three stages and the slope changes continuously during the transitions from axial compression to asymmetric deformation and from asymmetric deformation to axial stretching.

As discussed above, the normalized snap-through strength of uniform inclined guided beams of various angles is bound by 4π2, which significantly limits the strength and energy absorption capacity of the triangular units and, consequently, the disclosed structures and mechanisms. To remedy this, the inclined beam was replaced with a uniform cross-section in the design with a stepped beam comprising a relatively thick and rigid section in the middle and two sections of equal length with smaller cross-section on the two sides, as shown inFIG. 16B. The parameter R is defined as the ratio between the rigid section and the overall beam length, as shown in the inset ofFIG. 16B. As R approaches 1, the result is essentially a beam with two living hinges on each side, localizing the strain energy of the deformed structure at those regions.FIG. 16Bshows the force displacement response of inclined beams with α=15° for different values of R, illustrating that the snap-through strength and negative stiffness both significantly increase by increasing R. On the other hand, the localization of deformation at that hinges by increasing R can lead to their premature failure. For a given base material and hinge design (meaning given combinations of α and R), a critical hinge thickness will exist above which the material will yield or fracture upon snap-through, thus preventing reconfigurability. This critical condition was analytically studied and the results are shown inFIG. 16C, which plots the absorbed energy per unit volume (energy density) of the tessellated structure shown in the inset ofFIG. 16Duntil full densification (this energy is represented schematically by the hatched area in the figure inset) as a function of angle, a, and length ratio, R. The energy density is normalized by E(t/L)3, where E, t, and L denote the material Young's modulus, hinge thickness, and overall inclined beam length, respectively (note that energy scales with (t/L)3when t/L<<1). The at the top right hand corner of the plot bordered by the dashed line embodies combinations of R and α that are not kinematically feasible for a bistable mechanism because the length of the rigid section is so large (i.e., R>sin(α)) that it cannot rotate clear of the two side walls. The overlaid solid contour lines in the same figure show the critical hinge thickness ratio, tcr/L, normalized by the material yield strain, εy. Any thickness value greater than tcrwould cause the hinge to fail before snapping. Theoretical analysis that was conducted shows that, for linear elastic materials with relatively small values of elongation at failure (εy<0.1), a category that includes most available materials, the value of critical hinge thickness ratio, tcr/L, scales with εy. As a result, the maximum strength and dissipated energy per unit volume of the structure both scale with Eεy3. However, for εy>>1 (representative of many elastomers), the maximum strength and dissipated energy per unit volume both scale with ε63/2and the critical feature size scales with εy1/2. The appropriate base material, in general, should be chosen considering the tradeoff between maximizing the maximum allowable feature size (˜εy), thus requiring less sophisticated manufacturing techniques, and maximizing the structural performance (˜Eεy3).

Contrary to continuum systems with convex elastic energy, the stress-strain response and the hysteresis behavior of a chain of discrete bistable elements differs significantly from that of a single element. In order to study the behavior of a stack of bistable units, a numerical code was developed that enables calculation of the macroscopic behavior of material based on a generic stress-strain behavior of a single element obtained from the numerical method, without requiring tri-linear or cubic approximations.FIG. 16Dcompares the stress-strain response of a stack of 200 bistable units (n=200 curve) and a single unit under quasi-static displacement control compression (n=1 curve). Upon loading the stack, one or more of the bistable units that have the lowest strength values (e.g., due to material imperfections and geometrical variations) will snap through (collapse) first at a stress value close to the nominal strength, thereby causing the other cells in the stack to partially relax and the load to drop as shown by the curve inFIG. 16D. This sequence of gradual increase and sudden drop in the stack reaction force continues until all the cells in the stack collapse and full densification is reached. The resulting hysteresis from different paths during loading and unloading due to cell relaxation at a fix displacement renders the energy absorption capacity of the tessellated structure significantly higher than the sum of those of the individual units (i.e., the area under the n=200 curve). The difference in absorbed energy is dissipated through mechanical vibrations of the collapsing and relaxing cells at each load drop. This strategy can also be used to obtain a significant range of deformation at a relatively constant load. In human and animal muscle fibers, thousands of multistable titin molecules linked in series are responsible for creating a relatively constant reaction force over a significant range of tissue stretch, which is essential for muscle's passive elasticity.

For applications involving shape reconfigurability, the stability of the various deformed phases are critical. The phase stability in general is affected by the non-dimensional rigid section length, R, the hinge angle, α, and the hinge thickness ratio, t/l=t/L·((2/(1−R)), where l is the hinge length. InFIG. 17A, the phase stability parameter, defined as S2/S1, is plotted versus t/l and R for a constant α=15°. S1and S2denote the maximum and minimum force values, respectively, between the first and third equilibrium points. The figure shows three distinct regions of stability behavior. The region on the left is when the hinge thickness ratio is small and, therefore, the values of S1and negative stiffness are controlled by the symmetric bending of the beam in the negative stiffness (spinodal) phase. When the hinge thickness is greater than 0.17 and R is small, the structure is single stable and S2>0. The middle region represents cases in which the structure is bistable, however, the slope of the force-displacement curve is continuous due to a more significant contribution of axial stretching (e.g., t/l>√{square root over ((9α2)/(4π2sin (α)))} when R=0). The slope of the curve at different phases is critical to the multi-cell behavior of multistable unit chains. The results also show that the use of stepped beam (i.e., R>0) significantly expands the bistable region.

For energy absorption applications, juxtaposition of the performance of the proposed materials with the universe of existing materials is instructive.FIG. 17Bshows an Ashby map of absorbed energy per unit volume versus compressive strength. Materials in the top left corner of the map will be optimal from an impact-resistance perspective. Results for different base materials are presented: an elastomer (TPU), a metal (steel), and a ceramic (zirconia). The proposed shape-reconfigurable structures overlay part of performance region of elastomers and outperforms previously proposed micro-lattices with substantial recoverability from large strains including ultralight and hierarchical architected materials.

In summary, disclosed are multistable shape-reconfigurable structures and mechanisms based on a structural building blocks encompassing living hinges. One-dimensional, two-dimensional, and three-dimensional structures and mechanisms can be designed, enabling complex shape-morphing patterns. One of the key benefits of the designs is the reversibility between different stable states, implying that the original or deformed configurations of the structure can be infinitely recovered with no compromise on the efficiency, integrity or life of the structure. However, the localization of the majority of trapped strain energy on the hinges makes the failure strain of the hinge material critical to the viability of the proposed concept and imposes significant restraints on material selection. This requirement is material-specific. Reducing the feature size in these structures is shown to be a possible solution for creating hinges that will undergo snapping without plastic deformation. Both metals and ceramics generally become stronger as the critical length scale is reduced (by virtue of well-established size effects in plasticity and fracture), making the failure strain of the hinge material significantly higher at the nano-scale and thus resulting in more efficient multi stable designs. Reducing the size of the unit cell could also lead to increased smoothness of the outlines in the desired topologies, thus enabling better dimensional control. Finally, scale reduction in the unit cell generally results in a larger number of unit cells per unit volume in the macro-scale structure, which enhances energy dissipation in discrete materials systems with negative stiffness mechanisms.

In the discussion that follows, mathematical analysis is presented that supports the disclosure provided above. The analysis of the snap-through behavior of a bistable triangular unit with a vertical force F acting on the top (FIG. 18A) can be reduced to analysis of an inclined guided beam by virtue of the axial symmetry with respect to the center line of the structure and the fact that the triangle base is relatively rigid and thus cannot bend or stretch. Large deformations of an inclined guided uniform beam has been numerically studied before. Here we use the beam-deflection theorem to gain insight on the deformation modes and also to obtain closed-form solutions for the load-displacement response of an inclined guided beam with the rigid middle section.

Beam deflection or beam column formulas are nonlinear formulas linking the end rotations of an axially loaded beam to its end moments. For a single beam connecting nodes a and b under axial compressive force P and subjected to the two counter-clockwise end couples Maand Mb, the end rotations θaand θb(positive when counter-clockwise) relative to the line joining the displaced end nodes (seeFIG. 18C) can be obtained through the beam-column relations as:

Ma=EIℓ⁢(θa⁢Ψ⁡(q)-θb⁢Φ⁡(q)Ψ2⁡(q)-Φ2⁡(q))⁢⁢Mb=EIℓ⁢(θb⁢Ψ⁡(q)-θa⁢Φ⁡(q)Ψ2⁡(q)-Φ2⁡(q))(2)
From the beam-column theorem, the deflection of a column-beam can be calculated as:

y=-Mbρ⁢(sin⁢⁢k⁡(ℓ-x)sin⁢⁢k⁢⁢ℓ-ℓ-xℓ)+Maρ⁢(sin⁢⁢kxsin⁢⁢k⁢⁢ℓ-xℓ)(3)
which allows calculation of the beam axial contraction, Δl, in terms of beam end moments according to

In the case of the beam with the rigid middle section deformed asymmetrically as shown inFIG. 18D, the end moments Maand Mbcan be found by simultaneously solving the following set of 7 unknown (i.e. M,M′,γ,γ′,β,P and Q) and 7 equations:

q=ℓ⁢PEI.
Solving the system of equations (5) allows calculation of beam shrinkage, Δlasym, as a function of q from Eq. (4).

In the case of a beam with rigid middle section deformed symmetrically shown inFIG. 18E, each beam segment can be considered as a beam deformed asymmetrically with respect to its own axis shown by dashed lines (i.e., Ma=−Mb=M″). The deflection of the beam can be found by solving the following set of 2 equations with 2 unknowns (M″ and ξ):

where Note that since for the shrinkage due to symmetric deflection of the beam with rigid middle section the load parameter q′ is also a function of deflection angle, ξ, the unknowns need to be found through iterations. Now, Eq. (4) can be readily used to calculate the amount of shrinkage by substituting Ma=−Mb=M″ in Eq. (4). Note that the rigid body rotation of each segment of length e will also contribute to the total amount of shrinkage for the asymmetrical component of deformation, Δlsym.

For the axial component of deformation, the amount of shrinkage can be obtained as

Δ⁢⁢ℓaxial=P⁢⁢ℓEA.
Once Δlasym, Δlsymand Δlaxial, are found one can obtain the total amount of shrinkage of stepped beam as:
Δl=Δlasym+Δlsym+Δlaxial(7)
Concerning an inclined guided beam problem restrained between two vertical walls, the overall axial contraction of the beam can be geometrically expressed as:

Δ⁢⁢ℓ=ℓ⁡(1-cos⁢⁢(a)cos⁡(α-β))(8)
By equating the expressions of overall shrinkage of beam from Eqs. (7) and (8), the value of non-dimensional force parameter q and consequently internal beam forces are found.

Next, we present different characteristic contour plots for the snap-through response of an inclined guided beam (seeFIG. 19). These contour plots are obtained directly from the analytical solution described in the previous section and show different characteristic parameters in the load displacement response of an inclined guided beam versus different values of angle, α, and rigid section length ratio, R.FIGS. 19A-19Dshow normalized values of the initial slope, the snap-through strength, the slope at the third equilibrium point of the load-displacement curve and, the distance between the first and third equilibrium points, respectively. The value of initial slope is controlled by the stretching of the beam and therefore is normalized by

EAL,
where E is material Young's modulus, A is beams cross section and L is the overall beam length. The values of snap-through strength, slope of curve at third equilibrium and the distance between the first and third equilibrium points are controlled by the bending of the deformable beam segments (hinges) at small thicknesses of the two beam segments and therefore normalized by

EIL2,EIL3
and 2L sin α, respectively, where I is the second moment of inertia for the two deformable beam segments. The design maps inFIG. 19provide insight on optimum geometries for a range of different applications.

In the problem of an inclined guided beam under compressive loads, when the thickness of the beam normalized by beam length is small, the snap-through strength is determined by the symmetric buckling in the beam segments, as described in the main document. A schematic of such a response is shown inFIG. 20A, manifesting a discontinuity in the load-displacement curve at the maximum load. However, when the inclined beam thickness ratio is large enough, the symmetric buckling strength of the beam is higher than the maximum axial load induced in the guided beam during snap-through, and the general form of behavior changes. To study the latter, consider the simplified problem of force-displacement of an object that is only allowed to slide vertically and linked to an inclined linear spring of coefficient K1, as shown inFIG. 20B. The linear spring is in turn coupled with a rotational spring of coefficient K2. Satisfying the equilibrium for the object, the load-displacement response is obtained as:

Fma⁢⁢x=K1⁢L⁢⁢3⁢α316+K2L⁢α2(10)
For the problem of an inclined guided beam with aspect ratio of R and angle α with respect to horizontal line, the values of K1and K2can be approximated according to Euler-Bernoulli beam theory as

K1=EA2⁢ℓ⁢⁢K2=EI2⁢ℓ(11)
Substituting from Eq. (11) in Eq. (10), the value of Fmaxcan be approximated as

Fma⁢⁢x=4⁢π2⁢EI⁢⁢sin⁢⁢αL2⁡(1-R)2=π2⁢Ebt3⁢sin⁢⁢α3⁢L2⁡(1-R)2,
the critical thickness of the hinges that will cause the inclined beam to snap-through without buckling is obtained as:

tcrL=9⁢α3⁡(1-R)16⁢π2⁢sin⁢⁢α-2⁢(1-R)⁢α(13)
When t>tcr, the inclined guided beam will bend and shrink axially without any bifurcation happening at any stage through the snap-through process. The force-displacement response will be represented by a smooth curve without any slope discontinuity. Expressions (13) can be simplified to

As suggested by the beam-column formula (1), the deflection of a beam-column is determined by the normalized values of end beam moments, Ml/EI. Also, emergence of q as a non-dimensional parameter in the problem makes Pl2/EI a non-dimensional group affecting the problem. Similarly, by satisfying requirements of equilibrium, it can be shown that the amount of transverse load is linked to beam-deflection as Ql2/EI. Therefore, the deflection, shrinkage or curvature of a beam-column remains relate to the values of moment and force normalized by EI/l and EI/l2, respectively, neglecting the effect of axial shrinkage on the overall shrinkage of the beam.

Following the argument above, the amount of absorbed energy by deflection of a beam-column throughout snap-through for given R and a, described by the area under the force-displacement curve, is proportional to EI or Et3, where t is the hinge thickness shown inFIG. 16B.

As for the value of critical (minimum) hinge thickness causing failure in the hinges, the amount of maximum strain due to internal moments and forces can be written as a

ɛy=M*⁢t/2EI+P*Etb=M*2⁢(tℓ)+P*12⁢(tℓ)2(14)
where M*, P* are the maximum values of moment and force throughout snap-through of the inclined guided hinged beam and b is the hinge width. Eq. (7) can be re-written as:

t2=12P*⁢⁢and⁢⁢t1=2M*.
Equation (8) is a quadratic equation that has one positive root equal to:

As a result, when εy<<1 (which is the case for most existing materials), then the critical value of hinges thickness is proportional to εy; conversely, when εy>>1, the critical value of the hinge thickness is proportional to √{square root over (εy)}. Since values of trapped strain energy and strength are proportional to Et3, we can conclude that their maximum values occurring at the critical thickness are proportional to Eεy3.FIG. 21shows an Ashby map of Young's modulus versus strain at yield for existing materials. The dashed lines represent selection lines of constant Eεy3value. In the range of εy<<1, the three base materials of TPU (elastomer), steel (metal), and Zirconia (ceramic) were selected and their energy absorption and strength values were compared (seeFIG. 17B).

Contrary to continuum systems with convex elastic energy, the stress-strain response and the hysteric behavior of a chain of discrete bistable elements differs significantly from that of a single element. In order to study the behavior of a stack of bistable units a numerical code was developed that allows calculation of macroscopic behavior of material based on a generic stress-strain behavior of a single element obtained from the numerical method, not necessarily tri-linear or cubic approximations. The load-displacement response of a stack of bistable elements under quasi-static displacement control compression can be obtained from post processing of the response of a single element. In our method, finite element simulations were performed on the single bistable element and the load-displacement response was obtained. Beam elements (B21) were used to model the bistable unit. Each unit consists of a rigid base and two inclined beams as shown inFIG. 18Aand the downward vertical displacement, Δ, is applied on top of the element. The Riks analysis in ABAQUS software was used to capture the post-buckling behavior of the bistable elements. Note that a static, general solver cannot converge in the existence of the snap-through mechanism. The effective stress-strain response of a single bistable element (n=1) is shown by the curve inFIG. 22. The value of effective stress is defined by σ=F/Ewb where F is the vertical reaction force of the inclined beam, E is the Young's modulus of base material, w and b are the width and thickness of the beam, respectively. The value of effective strain is calculated as ε=Δ/nh, where Δ is vertical displacement of the stack, n is the number of elements and h is the element height. The mechanical response of a single element is partitioned into three phases: the initial section of the load-displacement curve with a positive slope (phase I), the spinodal phase of negative stiffness, and the section where the slope becomes positive again (phase II). The macroscopic behavior of a stack of discrete bistable elements is found using the algorithm described below.

Upon loading a stack of bistable elements, one or a few of the bistable units that have the least strength values (e.g., due to material imperfections, geometrical variations) will snap through (collapse) first around the nominal value of strength, causing the other elements in the stack to partially relax and the internal load to drop as shown by the blue curve inFIG. 16D. This sequential effect makes the state of the collapsing elements in the spinodal phase or phase II of response different at any time from the uncollapsed elements in phase I of response. As a result the collective stress-strain behavior of the stack different from the stress-strain response of a single element. To reflect this variation in our numerical simulation, a slight variation in the Young's modulus of the element of the stack is introduced.

During the loading of a stack of bistable elements under quasi-static compression when all the element are either in their phase I or phase II the displacement of the structure at any given load f (depicted inFIG. 22) can be found by:

ΔStructure=∑m=1i⁢xmII+∑k=i+1n⁢xkI(18)
where xkIand xkIIare the displacement of beam k, under load f in the phase I and phase II respectively, n is the number of the beams in the structure, and i is the number of the beams already entered phase II. However, when one of the bars enters its spinodal phase, the load displacement relation changes. In a stable configuration, only one bar at a time can enter its spinodal phase and other beans are either in phase I or phase II. When the collapsing bar emerges from the spinodal phase and enters its phase II of response, for every representative force f the displacement cam be expressed as:

Next we set to calculate the amount of stress relaxation due to snap-through of each bar. Note that at each load drop associated with snap-through of a bar in the stack the overall height of the stack remains constant. We satisfy this condition by first allowing the snap-through of the collapsing bar (shown in the stress-strain curve by path S) without any displacement constraints on the stack and next relaxing the internal forces of all the elements in the stack, which have equal internal forces due to equilibrium, until the pre-collapsed displacement of the stack is restored.

Satisfying expressions (18) and (19) for a tri-linear approximation of bistable element response with stress-strain slopes of kI, k8, kIIIin phase I, spinodal phase and phase II of element response as shown inFIG. 22, respectively, one can obtain analytical expressions for the magnitude of the mthload drop, dm, in a stack of n bistable elements (FIG. 16D) as:

1dm≃n-mkI⁢S+mkII⁢S(20)
where S is the length of the path S shown inFIG. 22.