U.S. patent number 10,513,089 [Application Number 14/879,035] was granted by the patent office on 2019-12-24 for self-transforming structures.
This patent grant is currently assigned to Carbitex, Inc., Massachusetts Institute of Technology. The grantee listed for this patent is Carbitex, Inc., Massachusetts Institute of Technology. Invention is credited to Junus Ali Khan, Athina Papadopoulou, Skylar J. E. Tibbits.
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United States Patent |
10,513,089 |
Tibbits , et al. |
December 24, 2019 |
Self-transforming structures
Abstract
A self-transforming structure is formed from a flexible, fibrous
composite having a weave pattern of fibers woven at intersecting
angles, the weave pattern having a boundary and one or more axes
for the fibers, and an added material coupled to the flexible,
fibrous composite to form a structure, wherein the flexible,
fibrous composite and the added material have different expansion
or contraction rates in response to an external stimulus to cause
the structure to self-transform, and wherein the added material has
a grain pattern oriented relative the weave pattern of the
flexible, fibrous composite. Applications of the self-transforming
structures include aviation, automotive, apparel/footwear,
furniture, and building materials. One particular example is for
providing adaptive control of fluid flow, such as in a jet engine
air inlet.
Inventors: |
Tibbits; Skylar J. E. (Boston,
MA), Papadopoulou; Athina (Cambridge, MA), Khan; Junus
Ali (Kennewick, WA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Massachusetts Institute of Technology
Carbitex, Inc. |
Cambridge
Kennewick |
MA
WA |
US
US |
|
|
Assignee: |
Massachusetts Institute of
Technology (Cambridge, MA)
Carbitex, Inc. (Kennewick, WA)
|
Family
ID: |
54542491 |
Appl.
No.: |
14/879,035 |
Filed: |
October 8, 2015 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20160101594 A1 |
Apr 14, 2016 |
|
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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62061197 |
Oct 8, 2014 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B
3/16 (20130101); B32B 5/18 (20130101); B32B
27/06 (20130101); B32B 5/024 (20130101); B32B
7/02 (20130101); B32B 5/02 (20130101); B32B
27/12 (20130101); B32B 27/34 (20130101); Y10T
428/24942 (20150115); B32B 2605/18 (20130101); B33Y
80/00 (20141201); Y10T 428/24802 (20150115); B32B
2262/106 (20130101); B32B 2605/08 (20130101); B32B
2437/02 (20130101); B32B 2437/00 (20130101); B32B
2307/518 (20130101); B32B 2419/00 (20130101); B32B
2307/52 (20130101); B32B 2479/00 (20130101) |
Current International
Class: |
B32B
7/02 (20190101); B32B 5/02 (20060101); B32B
5/18 (20060101); B32B 27/34 (20060101); B32B
3/16 (20060101); B32B 27/12 (20060101); B32B
27/06 (20060101); B33Y 80/00 (20150101) |
References Cited
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Oct 2018 |
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WO |
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|
Primary Examiner: Higgins; Gerard
Attorney, Agent or Firm: Hamilton, Brook, Smith &
Reynolds, P.C.
Parent Case Text
RELATED APPLICATION(S)
This application claims the benefit of U.S. Provisional Application
No. 62/061,197, filed on Oct. 8, 2014. The entire teachings of the
above application are incorporated herein by reference.
Claims
What is claimed is:
1. A self-transforming structure comprising: a) a flexible, carbon
fiber composite having a boundary and fibers along one or more
axes; and b) an added material having a boundary and a grain
pattern, wherein the added material is selected from the group
consisting of nylon, biaxially-oriented polyethylene terephthalate
(BoPET) and polypropylene, the grain pattern consisting of
substantially parallel grains, the added material coupled to a
surface of the flexible, carbon fiber composite to form a
structure, the flexible, carbon fiber composite and the added
material having different coefficients of expansion in response to
an external stimulus to cause the structure to self-transform, the
grain pattern of the added material oriented relative to the fibers
of the flexible, carbon fiber composite to enable predictable
self-transformation of the structure responsive to the external
stimulus.
2. The self-transforming structure of claim 1, wherein the fibers
of the flexible, carbon fiber composite are oriented biaxially.
3. The self-transforming structure of claim 2, wherein the grain
pattern of the added material is orthogonal to an axis of a fiber
of the flexible, carbon fiber composite.
4. The self-transforming structure of claim 2, wherein the grain
pattern of the added material is 45.degree. to an axis of a fiber
of the flexible, carbon fiber composite.
5. The self-transforming structure of claim 2, wherein the grain of
the added material is oriented at a 45.degree. angle to the
boundary of the flexible, carbon fiber composite.
6. The self-transforming structure of claim 2, wherein the grain of
the added material is orthogonal to the boundary of the flexible,
carbon fiber composite.
7. The self-transforming structure of claim 2, wherein the length
of the boundary of the added material is shorter than the length of
the boundary of the flexible, carbon fiber composite.
8. The self-transforming structure of claim 2, wherein the length
of the boundary of the added material is the same as the length of
the boundary of the flexible, carbon fiber composite.
9. The self-transforming structure of claim 2, wherein the fibers
of the flexible, carbon fiber composite are oriented at 45.degree.
angles relative to the boundary of the flexible, carbon fiber
composite.
10. The self-transforming structure of claim 2, wherein the fibers
of the flexible, carbon fiber composite are orthogonal to the
boundary of the flexible, carbon fiber composite.
11. The self-transforming structure of claim 2, wherein the
flexible, carbon fiber composite is square, rectangular, or
round.
12. The self-transforming structure of claim 2, wherein the
flexible, carbon fiber composite is rectangular.
13. The self-transforming structure of claim 2, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at 45.degree. relative to the boundary of the
flexible, carbon fiber composite; c) the length of the boundary of
the added material is shorter than the length of the boundary of
the flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are oriented at 45.degree.
relative to the boundary of the flexible, carbon fiber
composite.
14. The self-transforming structure of claim 2, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at 45.degree. relative to the boundary of the
flexible, carbon fiber composite; c) the length of the boundary of
the added material is the same as the length of the boundary of the
flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are oriented at 45.degree.
relative to the boundary of the flexible, carbon fiber
composite.
15. The self-transforming structure of claim 2, wherein: a) the
grain of the added material is orthogonal relative to an axis of a
fiber of the flexible, carbon fiber composite; b) the grain of the
added material is orthogonal relative to the boundary of the
flexible, carbon fiber composite; c) the length of the boundary of
the added material is shorter than the length of the boundary of
the flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are orthogonal relative to the
boundary of the flexible, carbon fiber composite.
16. The self-transforming structure of claim 2, wherein: a) the
grain of the added material is oriented at a 45.degree. angle
relative to an axis of a fiber of the flexible, carbon fiber
composite; b) the grain of the added material is orthogonal
relative to the boundary of the flexible, carbon fiber composite;
c) the length of the boundary of the added material is the same
length as the boundary of the flexible, carbon fiber composite; and
d) the fibers of the flexible, carbon fiber composite are oriented
at a 45.degree. angle relative to the boundary of the flexible,
carbon fiber composite.
17. The self-transforming structure of claim 13, wherein
substantially parallel grains of the added material are on opposite
surfaces of the flexible, carbon fiber composite.
18. The self-transforming structure of claim 5, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at 45.degree. relative to the boundary of the
flexible, carbon fiber composite; c) the length of the boundary of
the added material is the same as the length of the boundary of the
flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are oriented at 45.degree.
relative to the boundary of the flexible, carbon fiber composite,
and wherein the added material provides equal forces in two
directions, thereby providing bi-stability.
19. The self-transforming structure of claim 1, wherein the fibers
of the flexible, carbon fiber composite are oriented
triaxially.
20. The self-transforming structure of claim 19, wherein the grain
of the added material is orthogonal to an axis of a fiber of the
flexible, carbon fiber composite.
21. The self-transforming structure of claim 19, wherein the grain
of the added material is oriented at an angle of 0.degree.,
60.degree., or 120.degree. relative to the boundary of the
flexible, carbon fiber composite.
22. The self-transforming structure of claim 19, wherein the length
of the boundary of the added material is the same length as the
boundary of the flexible, carbon fiber composite.
23. The self-transforming structure of claim 19, wherein the fibers
of the flexible, carbon fiber composite are oriented at 60.degree.
and 120.degree. angles relative to the boundary of the flexible,
carbon fiber composite.
24. The self-transforming structure of claim 19, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at a 0.degree. angle relative to the boundary
of the flexible, carbon fiber composite; c) the length of the
boundary of the added material is the same length as the boundary
of the flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are oriented at 60.degree. and
120.degree. angles relative to the boundary of the flexible, carbon
fiber composite.
25. The self-transforming structure of claim 19, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at a 60.degree. angle relative to the boundary
of the flexible, carbon fiber composite; c) the length of the
boundary of the added material is the same length as the boundary
of the flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are oriented at 60.degree. and
120.degree. angles relative to the boundary of the flexible, carbon
fiber composite.
26. The self-transforming structure of claim 19, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at a 120.degree. angle relative to the
boundary of the flexible, carbon fiber composite; c) the length of
the boundary of the added material is the same length as the
boundary of the flexible, carbon fiber composite; and d) the fibers
of the flexible, carbon fiber composite are oriented at 60.degree.
and 120.degree. angles relative to the boundary of the flexible,
carbon fiber composite.
27. The self-transforming structure of claim 1, wherein the fibers
of the flexible, carbon fiber composite are uniaxial.
28. The self-transforming structure of claim 27, wherein the grain
of the added material is orthogonal to an axis of a fiber of the
flexible, carbon fiber composite.
29. The self-transforming structure of claim 27, wherein the grain
of the added material is oriented at an angle of 0.degree.,
orthogonal, or 45.degree. relative to the boundary of the flexible,
carbon fiber composite.
30. The self-transforming structure of claim 27, wherein the length
of the boundary of the added material is the same length as the
boundary of the flexible, carbon fiber composite.
31. The self-transforming structure of claim 27, wherein the fibers
of the flexible, carbon fiber composite are orthogonal relative to
the boundary of the flexible, carbon fiber composite.
32. The self-transforming structure of claim 27, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at a 0.degree. angle relative to the boundary
of the flexible, carbon fiber composite; c) the length of the
boundary of the added material is the same length as the boundary
of the flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are orthogonal to the boundary of
the flexible, carbon fiber composite.
33. The self-transforming structure of claim 27, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is orthogonal to the boundary of the flexible, carbon
fiber composite; c) the length of the boundary of the added
material is the same length as the boundary of the flexible, carbon
fiber composite; and d) the fibers of the flexible, carbon fiber
composite are orthogonal to the boundary of the flexible, carbon
fiber composite.
34. The self-transforming structure of claim 27, wherein: a) the
grain of the added material is orthogonal to an axis of a fiber of
the flexible, carbon fiber composite; b) the grain of the added
material is oriented at a 45.degree. angle relative to the boundary
of the flexible, carbon fiber composite; c) the length of the
boundary of the added material is the same length as the boundary
of the flexible, carbon fiber composite; and d) the fibers of the
flexible, carbon fiber composite are orthogonal to the boundary of
the flexible, carbon fiber composite.
35. The self-transforming structure of claim 1, wherein the
external stimulus can be exposure to a temperature change.
36. The self-transforming structure of claim 35, wherein the
temperature change can be caused by a laser, infrared light, or
electrical resistive heating.
37. The self-transforming structure of claim 1, wherein the
external stimulus can be exposure to water or removal of exposure
to water.
38. A method of making a self-transforming structure, the method
comprising: coupling an added material to a surface of a flexible,
carbon fiber composite to form a structure, the flexible, carbon
fiber composite having a boundary and fibers along one or more
axes, wherein the added material is selected from the group
consisting of nylon, biaxially-oriented polyethylene terephthalate
(BoPET) and polypropylene, wherein the added material has a
boundary and a grain pattern, the grain pattern consisting of
substantially parallel grains, wherein the flexible, carbon fiber
composite and the added material have different coefficients of
expansion in response to an external stimulus to cause the
structure to self-transform, and wherein the grain pattern of the
added material is oriented relative to the fibers of the flexible,
carbon fiber composite to enable predictable self-transformation of
the structure responsive to the external stimulus.
39. The method of claim 38, wherein coupling the added material to
the flexible, carbon fiber composite comprises printing the added
material onto the flexible, carbon fiber composite by additive
manufacturing.
40. The method of claim 38, wherein coupling the added material to
the flexible, carbon fiber composite comprises laminating the added
material onto the flexible, carbon fiber composite.
Description
BACKGROUND OF THE INVENTION
Additive manufacturing, sometimes referred to as "3D printing,"
permits the precise application of materials onto substrates.
Recent advances in 3D printing have enabled the fabrication of
printed objects encoded with predicted shape change. These objects
can transform over time from a first, printed shape to a second,
predetermined shape.
SUMMARY OF THE INVENTION
Described herein is a self-transforming structure. The
self-transforming structure includes a flexible, fibrous composite
having a boundary and fibers along one or more axes that form a
weave pattern, and an added material having a grain pattern. The
added material can be coupled to the flexible, fibrous composite to
form a structure. The flexible, fibrous composite and the added
material have different expansion or contraction rates in response
to an external stimulus to cause the structure to self-transform.
The grain pattern of the added material can be oriented relative
the weave pattern of the flexible, fibrous composite to cause a
predictable self-transformation of the structure responsive to the
external stimulus. The flexible, fibrous composite can be carbon
fiber, glass fiber, basalt fiber, liquid crystal polymers, and
hybrids thereof.
The weave pattern of the flexible, fibrous composite can be
biaxial. The grain pattern of the added material can be orthogonal,
oriented at a 45.degree. angle, or oriented at any other angle to
an axis of a fiber of the flexible, fibrous composite. The grain
pattern of the added material can be 45.degree. to an axis of a
fiber of the flexible, fibrous composite. The grain of the added
material can be oriented at a 45.degree. angle to a boundary of the
flexible, fibrous composite. The grain of the added material can be
orthogonal to a boundary of the flexible, fibrous composite. The
length of the boundary of the added material can be shorter than
the length of the boundary of the flexible, fibrous composite. The
length of the boundary of the added material can be the same as the
length of the boundary of the flexible, fibrous composite. The
fibers of the flexible, fibrous added material can be oriented at
45.degree. angles relative to the boundary of the flexible, fibrous
composite. The fibers of the flexible, fibrous added material can
be orthogonal to the boundary of the flexible, fibrous composite.
The flexible, fibrous composite can be square, rectangular, round,
or an arbitrary shape. The flexible, fibrous composite can be
rectangular.
In one embodiment having a biaxial, flexible fibrous composite, a)
the grain of the added material can be orthogonal to an axis of a
fiber of the flexible, fibrous composite; b) the grain of the added
material can be oriented at 45.degree. relative to the boundary of
the flexible, fibrous composite; c) the length of the boundary of
the added material can be shorter than the length of the boundary
of the flexible, fibrous composite; and d) the fibers of the
flexible, fibrous composite can be oriented at 45.degree. relative
to the boundary of the flexible, fibrous composite.
In another embodiment having a biaxial, flexible fibrous composite,
a) the grain of the added material can be orthogonal to an axis of
a fiber of the flexible, fibrous composite; b) the grain of the
added material can be oriented at 45.degree. relative to the
boundary of the flexible, fibrous composite; c) the length of the
boundary of the added material can be the same as the length of the
boundary of the flexible, fibrous composite; and d) the fibers of
the flexible, fibrous composite are oriented at 45.degree. relative
to the boundary of the flexible, fibrous composite.
In another embodiment having a biaxial, flexible fibrous composite,
a) the grain of the added material can be orthogonal relative to an
axis of a fiber of the flexible, fibrous composite; b) the grain of
the added material can be orthogonal relative to the boundary of
the flexible, fibrous composite; c) the length of the boundary of
the added material can be shorter than the length of the boundary
of the flexible, fibrous composite; and d) the fibers of the
flexible, fibrous composite are orthogonal relative to the boundary
of the flexible, fibrous composite.
In another embodiment having a biaxial, flexible fibrous composite,
a) the grain of the added material can be oriented at a 45.degree.
angle relative to an axis of a fiber of the flexible, fibrous
composite; b) the grain of the added material can be orthogonal
relative to the boundary of the flexible, fibrous composite; c) the
length of the boundary of the added material can be the same length
as the boundary of the flexible, fibrous composite; and d) the
fibers of the flexible, fibrous composite are oriented at a
45.degree. angle relative to the boundary of the flexible, fibrous
composite. In some instances, parallel grains of the added material
can be on opposite sides of the flexible, fibrous composite.
In another embodiment having a biaxial, flexible fibrous composite,
a) the grain of the added material can be orthogonal to an axis of
a fiber of the flexible, fibrous composite; b) the grain of the
added material can be oriented at 45.degree. relative to the
boundary of the flexible, fibrous composite; c) the length of the
boundary of the added material can be the same as the length of the
boundary of the flexible, fibrous composite; and d) the fibers of
the flexible, fibrous composite are oriented at 45.degree. relative
to the boundary of the flexible, fibrous composite. Additionally,
the added material can provide equal forces in two directions,
thereby providing bi-stability.
The weave pattern of the flexible, fibrous composite can be
triaxial. The grain of the added material can be orthogonal to an
axis of a fiber of the flexible, fibrous composite. The grain of
the added material can be oriented at an angle of 0.degree.,
60.degree., or 120.degree. relative to the boundary of the
flexible, fibrous composite. The length of the boundary of the
added material can be the same length as the boundary of the
flexible, fibrous composite. The fibers of the flexible, fibrous
composite are oriented at 60.degree. and 120.degree. angles
relative to the boundary of the flexible, fibrous composite.
In one embodiment having a triaxial, flexible fibrous composite, a)
the grain of the added material can be orthogonal to an axis of a
fiber of the flexible, fibrous composite; b) the grain of the added
material can be oriented at a 0.degree. angle relative to the
boundary of the flexible, fibrous composite; c) the length of the
boundary of the added material can be the same length as the
boundary of the flexible, fibrous composite; and d) the fibers of
the flexible, fibrous composite are oriented at 60.degree. and
120.degree. angles relative to the boundary of the flexible,
fibrous composite.
In one embodiment having a triaxial, flexible fibrous composite, a)
the grain of the added material can be orthogonal to an axis of a
fiber of the flexible, fibrous composite; b) the grain of the added
material can be oriented at a 60.degree. angle relative to the
boundary of the flexible, fibrous composite; c) the length of the
boundary of the added material can be the same length as the
boundary of the flexible, fibrous composite; and d) the fibers of
the flexible, fibrous composite are oriented at 60.degree. and
120.degree. angles relative to the boundary of the flexible,
fibrous composite.
In one embodiment having a triaxial, flexible fibrous composite, a)
the grain of the added material can be orthogonal to an axis of a
fiber of the flexible, fibrous composite; b) the grain of the added
material can be oriented at a 120.degree. angle relative to the
boundary of the flexible, fibrous composite; c) the length of the
boundary of the added material can be the same length as the
boundary of the flexible, fibrous composite; and d) the fibers of
the flexible, fibrous composite are oriented at 60.degree. and
120.degree. angles relative to the boundary of the flexible,
fibrous composite.
The weave pattern of the flexible, fibrous composite can be
uniaxial. The grain of the added material can be orthogonal to an
axis of a fiber of the flexible, fibrous composite. The grain of
the added material can be oriented at an angle of 0.degree.,
orthogonal, or 45.degree. relative to the boundary of the flexible,
fibrous composite. The length of the boundary of the added material
can be the same length as the boundary of the flexible, fibrous
composite. The fibers of the flexible, fibrous composite can be
orthogonal relative to the boundary of the flexible, fibrous
composite.
In one embodiment having a uniaxial, flexible fibrous composite, a)
the grain of the added material can be orthogonal to an axis of a
fiber of the flexible, fibrous composite; b) the grain of the added
material can be oriented at a 0.degree. angle relative to the
boundary of the flexible, fibrous composite; c) the length of the
boundary of the added material can be the same length as the
boundary of the flexible, fibrous composite; and d) the fibers of
the flexible, fibrous composite can be orthogonal to the boundary
of the flexible, fibrous composite.
In one embodiment having a uniaxial, flexible fibrous composite, a)
the grain of the added material can be orthogonal to an axis of a
fiber of the flexible, fibrous composite; b) the grain of the added
material can be orthogonal to the boundary of the flexible, fibrous
composite; c) the length of the boundary of the added material can
be the same length as the boundary of the flexible, fibrous
composite; and d) the fibers of the flexible, fibrous composite can
be orthogonal to the boundary of the flexible, fibrous
composite.
In one embodiment having a uniaxial, flexible fibrous composite, a)
the grain of the added material can be orthogonal to an axis of a
fiber of the flexible, fibrous composite; b) the grain of the added
material can be oriented at a 45.degree. angle relative to the
boundary of the flexible, fibrous composite; c) the length of the
boundary of the added material can be the same length as the
boundary of the flexible, fibrous composite; and d) the fibers of
the flexible, fibrous composite can be orthogonal to the boundary
of the flexible, fibrous composite.
The external stimulus can be exposure to a temperature change. In
some instances, exposure to a temperature change can be caused by a
laser, infrared light, or electrical resistive heating. The
external stimulus can be exposure to water or removal of exposure
to water.
Described herein is a method of making a self-transforming
structure. The method can include coupling an added material to a
flexible, fibrous composite to form a structure. The flexible,
fibrous composite can have a boundary and fibers along axes that
form a weave pattern. The flexible, fibrous composite and the added
material can have different expansion or contraction rates in
response to an external stimulus to cause the structure to
self-transform. The added material can have a grain pattern
oriented relative the weave pattern of the flexible, fibrous
composite. Coupling the added material to the flexible, fibrous
composite can include printing the added material onto the
flexible, fibrous composite by additive manufacturing. Coupling the
added material to the flexible, fibrous composite can include
laminating the added material onto the flexible, fibrous
composite.
The methods and resulting products described herein provide
numerous advantages compared to prior 3D printed structures.
Flexible, fibrous composite composites have an ordered structure
that provides strength and elasticity, which provide benefits in
self-transforming structures. The self-transforming structure can
be packaged in a flat configuration, and later transformed into a
three-dimensional structure at a later time or at a different
location.
The self-transforming structures described herein have applications
in numerous industries, including aviation, automotive,
apparel/footwear, furniture, and building materials.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be apparent from the following more particular
description of example embodiments of the invention, as illustrated
in the accompanying drawings in which like reference characters
refer to the same parts throughout the different views. The
drawings are not necessarily to scale, emphasis instead being
placed upon illustrating embodiments of the present invention.
FIG. 1 is an illustration of an embodiment showing
self-transformation angles. The angle of self-transformation (a)
varies depending on the width (b) of the added material.
FIGS. 2A-G are illustrations of transformations on a biaxial
fibrous composite: 2A) Fold; 2B) Curve; 2C) Twist; 2D) Spiral; 2E)
Wave; 2F) Bi-stable transformation; G) Fold.
FIGS. 3A-C are illustrations of transformation on a triaxial
fibrous composite: 3A) Curve; 3B) Curve; 3C) Curve.
FIGS. 4A-C are illustrations of transformations on a uniaxial
fibrous composite: 4A) Curve; 4B) Curve; 4C) Bi-stable
transformation.
FIG. 5 is an annotated photograph of an experimental setup for
making a self-transforming structure.
FIGS. 6A-C are photographs of observed transformation for one inch,
two inch, and three inch nylon strips laminated onto a four
inch-by-four inch flexible carbon fiber sample at 280.degree. F.
for 300 seconds.
FIGS. 7A-C are photographs of observed transformation for one inch,
two inch, and three inch nylon strips laminated onto a four
inch-by-four inch flexible carbon fiber sample at 400.degree. F.
for 300 seconds.
FIGS. 8A and 8B are illustrations showing nylon coupled to a carbon
fiber. FIG. 8A shows nylon adjacent to carbon fiber prior to
lamination. FIG. 8B shows nylon coupled to carbon fiber after
lamination and the shape transformation that has occurred.
FIG. 9 is an annotated photograph of an experimental setup for
observing temperature-dependent self-transformation.
FIGS. 10A-I are a series of photographs showing the transformation
over time (mm:ss). A) Time=0:00, Temperature=83.degree. F.; B)
Time=1:00, Temperature=119.degree. F.; C) Time=2:00,
Temperature=150.degree. F.; D) Time=3:00, Temperature=187.degree.
F.; E) Time=4:00, Temperature=221.degree. F.; F) Time=5:00,
Temperature=240.degree. F.; G) Time=7:00, Temperature=246.degree.
F.; H) Time=10:12, Temperature=261.degree. F.; I) Time=10:32,
Temperature=273.degree. F.
FIG. 11 is a graph showing the change in the angle of
self-transformation as temperature increases.
FIG. 12A is a series of time-lapsed photographs showing a twisting
transformation. FIG. 12B shows superimposed photos of a time-lapsed
twisting transformation.
FIG. 13A is a series of time-lapsed photographs showing a folding
transformation. FIG. 13B shows superimposed photos of a time-lapsed
folding transformation.
FIG. 14 is a time-lapse photograph showing the self-transformation
of programmable carbon fiber within a jet engine air inlet. The
dynamic carbon fiber regulates the amount of airflow for active
engine cooling.
FIG. 15 is an example of a triaxial weave with 22 mm wide strips of
fiber woven in 0 degree, +60 degree and -60 degree orientation. The
laminated sheet on top of the weave can be placed in-line with the
fiber orientation at 0.degree., 120.degree., or 60.degree. to
achieve a 1-curve, 2-curve, or 3-curve type behavior,
respectively.
FIG. 16 is an example of a uniaxial weave orientation. The print
pattern on top of the weave can be placed in-line with the fiber
orientation or at 90.degree. to achieve a 1-fold or 2-fold type
behavior, respectively.
FIGS. 17A and 17B are photographs of self-transforming structures
made using a triaxial flexible, fibrous composite. The grain
direction of the added material is indicated with arrows and is
patterned as illustrated in FIG. 3A.
FIGS. 18A-D are photographs of self-transforming structures made
using a biaxial flexible, fibrous composite. A) Curve; B) Fold; C)
Wave; D) Spiral.
DETAILED DESCRIPTION OF THE INVENTION
A description of example embodiments of the invention follows.
Self-transforming structures according to example embodiments can
be made according to the processes described herein. In general, a
flexible, fibrous composite provides a substrate for an added
material. Together, the flexible, fibrous composite and the added
material form a combined structure. The flexible, fibrous composite
and the added material typically have different expansion or
contraction rates in response to an external stimulus, which causes
the combined structure to self-transform upon exposure to the
external stimulus.
As used herein, the term "weave pattern" refers to an ordered
arrangement of fibers, which can be intersecting or
non-intersecting. Examples of intersecting weave patterns include
biaxial and triaxial weave patterns. An example of a
nonintersecting weave pattern is a uniaxial weave pattern.
As used herein, a "flexible, fibrous composite" is a composite that
provides sufficient ability to bend without delaminating or
detaching from the added material coupled to it. Thus, when the
self-transforming structure is exposed to an external stimulus,
thereby causing the flexible, fibrous composite and the added
material to have different expansion or contraction rates, the
added material remains laminated or coupled to the flexible,
fibrous composite, thereby causing a transformation in shape.
Methods of making a flexible, fibrous composite are described in
U.S. Patent Publication No. 2015/0174885.
Typically, a flexible, fibrous composite has at least one boundary,
and often times more than one boundary. For example, a circular
flexible, fibrous composite, as well as flexible fibrous composites
having complex curved shapes, have a single boundary. A triangular
flexible, fibrous composite has three boundaries. While many of the
embodiments described herein are square or rectangular, the
principles described are equally applicable to flexible, fibrous
composites having other geometric shapes, as well as to flexible,
fibrous composites having complex shapes. In these instances,
descriptions of orientations relative to a boundary refer to the
orientation at any position along a boundary.
Biaxial Weave Patterns and Oriented, Added Material
Typically, the flexible, fibrous composite is formed of woven
fibers. A variety of weave patterns are known in the art. The weave
patterns described herein are generally referred to as uniaxial,
biaxial, and triaxial. The added material is typically applied to
the flexible, fibrous composite so that grains of the added
material are patterned relative to the weave pattern.
FIG. 1 is an illustration of one embodiment of a self-transforming
structure 100. The flexible, fibrous composite 110 forms a
substrate for grains 130 of the added material. The flexible
fibrous composite is formed of intersecting fibers 115a and 115b.
In this particular embodiment, the fibers intersect at 90.degree.
angles, though other angles of intersection are possible. In the
particular example, the grains 130 of the added material are
substantially parallel with the fibers 115a of the flexible,
fibrous composite 110. In this embodiment, parallel grains of the
added material are aligned with and at least partially overlay
fibers 115a of the flexible, fibrous composite.
Unique orientations of the grain of the added material relative to
the axis of the flexible, fibrous substrate can yield different
transformations upon exposure to an external stimulus.
Conceptually, four features define the relationship between a
biaxial flexible, fibrous composite and the added material. First
is the relationship of the grain pattern of the added material to
an axis of a fiber of the flexible, fibrous composite. The grain
pattern of the added material can be orthogonal to an axis of a
fiber of the flexible fibrous composite, or it can be patterned at
an angle, such as a 45.degree. angle, relative to an axis of the
flexible fibrous composite. Second is the orientation of the grain
of the added material relative to a boundary of the flexible,
fibrous composite. The grain of the added material can be
orthogonal at a boundary, or it can be patterned at an angle, such
as a 45.degree. angle, relative to a boundary of the flexible,
fibrous composite. Third is the length of a boundary of the added
material in relation to the length of a boundary of the flexible,
fibrous composite. The length of a boundary of the added material
can be the same length as the length of a boundary of the flexible,
fibrous composite. Alternatively, the length of a boundary of the
added material can be shorter than a boundary of the flexible,
fibrous composite. Fourth is the orientation of the fibers of the
flexible, fibrous composite relative to a boundary of the flexible,
fibrous composite. The fibers of the flexible, fibrous composite
can be orthogonal to a boundary of the flexible, fibrous composite.
Alternatively, the fibers of the flexible, fibrous composite can be
angled, such as at a 45.degree. angle, relative to a boundary of
the flexible, fibrous composite. As another optional fifth
condition, the added material can be printed on opposing sides of
the flexible, fibrous composite, one particular example of which is
illustrated in FIG. 2E.
FIGS. 2A-F show six different types of transformations that can be
created. In general, FIGS. 2A-F show the relative orientation of a
biaxial flexible, fibrous composite and the added material that is
coupled to it. The relationship between the four features described
in the preceding paragraph and the embodiments of FIGS. 2A-F are
summarized in Table 1. The notation underneath the images in the
figures indicates the orientation of the fibers of the flexible
fibrous composite (left) and the grains of the added material
(middle) in degrees (e.g., in FIG. 2A, the orientation of the
fibers is at a 45 degree angle relative to the horizon, and the
orientation of the grains is also at a 45 degree angle relative to
the horizon).
TABLE-US-00001 TABLE 1 Features of biaxial flexible, fibrous
composite and added material illustrated in FIGS. 2A-F. 3. Length
of a 1. Relationship of 2. Orientation of boundary of the 4.
Orientation of the grain pattern the grain of the added material
the fibers of the of added material added material in relation to
flexible, fibrous to an axis of a relative to a the length of a
composite relative fiber of the boundary of the boundary of the to
a boundary of the FIG. and flexible, fibrous flexible, fibrous
flexible, fibrous flexible, fibrous Transformation composite
composite composite composite 2A: Fold Orthogonal 45.degree. to one
another Shorter 45.degree. to one another 2B: Curve Orthogonal
45.degree. to one another Same length 45.degree. to one another 2C:
Twist Orthogonal Orthogonal Shorter Orthogonal 2D: Spiral
45.degree. to one another Orthogonal Same length 45.degree. to one
another 2E: Wave Orthogonal 45.degree. to one another Shorter
45.degree. to one another 2F: Bi-stable Orthogonal 45.degree. to
one another Same length 45.degree. to one another 2G: Fold
Orthogonal 45.degree. to two Shorter 45.degree. to one another
boundaries
FIG. 2A shows a fold transformation. Parallel grains 130 of the
added material are orthogonal to an axis of a fiber 115a of the
flexible, fibrous composite, and coaxial with an axis of the other
fiber 115b. The grain 130 of the added material is oriented at a
45.degree. angle relative to its own boundary 135 and relative to
the boundary 120 of the flexible, fibrous composite. The length of
a boundary 135 of the added material 130 is shorter than the length
of a boundary 120 of the flexible, fibrous composite. The fibers
115a and 115b of the flexible, fibrous composite are oriented at a
45.degree. angle relative to its own boundary 120. In this
particular example, the flexible, fibrous composite 110 is square;
however, it need not be square in order to achieve a folding
transformation.
FIG. 2B shows a curve transformation. Parallel grains 130 of the
added material are orthogonal to an axis of a fiber 115a of the
flexible, fibrous composite, and coaxial with an axis of the other
fiber 115b. The grain 130 of the added material is oriented at a
45.degree. angle relative to its own boundary 135 and relative to
the boundary 120 of the flexible, fibrous composite. The length of
a boundary 135 of the added material 130 is the same, or
substantially the same, as the length of a boundary 120 of the
flexible, fibrous composite. The fibers 115a and 115b of the
flexible, fibrous composite are oriented at a 45.degree. angle
relative to its own boundary 120. In this particular example, the
flexible, fibrous composite 110 is square; however, it need not be
square in order to achieve a folding transformation. Unlike the
fold shown in FIG. 2A, a curve can occur when the added material
covers all, or substantially all, of a surface of the flexible,
fibrous composite.
FIG. 2C shows a twist transformation. Parallel grains 130 of the
added material are orthogonal to an axis of a fiber 115a of the
flexible, fibrous composite, and coaxial with an axis of the other
fiber 115b. The grain 130 of the added material is oriented
orthogonally relative to its own boundary 135 and relative to the
boundary 120 of the flexible, fibrous composite. The length of a
boundary 135 of the added material 130 is shorter than the length
of a boundary 120 of the flexible, fibrous composite. The fibers
115a and 115b of the flexible, fibrous composite are oriented
orthogonally relative to its own boundary 120. The flexible,
fibrous composite 110 is square; however, it need not be square in
order to achieve a twist transformation.
FIG. 2D shows a spiral transformation. Parallel grains 130 of the
added material are oriented at 45.degree. angles relative to both
axes of fiber 115a and 115b of the flexible, fibrous composite. The
grain 130 of the added material is oriented orthogonally relative
to its own boundary 135 and relative to the boundary 120 of the
flexible, fibrous composite. The length of a boundary 135 of the
added material 130 is the same as, or substantially similar to, the
length of a boundary 120 of the flexible, fibrous composite. The
fibers 115a and 115b of the flexible, fibrous composite are
oriented at 45.degree. angles relative to its own boundary 120.
Unlike the twist shown in FIG. 2C, a spiral can occur when the
added material covers all, or substantially all, of a surface of
the flexible, fibrous composite.
FIG. 2E shows a wave transformation. Parallel grains 130 of the
added material are orthogonal to an axis of a fiber 115a of the
flexible, fibrous composite, and coaxial with an axis of the other
fiber 115b. The grain 130 of the added material is oriented at a
45.degree. angle relative to its own boundary 135 and relative to
the boundary 120 of the flexible, fibrous composite. The length of
a boundary 135 of the added material 130 is shorter than the length
of a boundary 120 of the flexible, fibrous composite. The fibers
115a and 115b of the flexible, fibrous composite are oriented at a
45.degree. angle relative to its own boundary 120. The flexible,
fibrous composite 110 is square; however, it need not be square in
order to achieve a folding transformation. Conceptually, FIG. 2E
builds upon FIG. 2A because it can be used to create two
transformations like FIG. 2A, but on opposite sides of a flexible,
fibrous composite. Although not illustrated, the added material can
be oriented in different patterns on the first and sides of the
flexible, fibrous composite, thereby creating even more unique
structures.
FIG. 2F shows a bi-stable configuration. Parallel grains 130 of the
added material are orthogonal to an axis of a fiber 115a of the
flexible, fibrous composite, and coaxial with an axis of the other
fiber 115b. The grain 130 of the added material is oriented at a
45.degree. angle relative to its own boundary 135 and relative to
the boundary 120 of the flexible, fibrous composite. The length of
a boundary 135 of the added material 130 is the same, or
substantially the same, as the length of a boundary 120 of the
flexible, fibrous composite. The fibers 115a and 115b of the
flexible, fibrous composite are oriented at a 45.degree. angle
relative to its own boundary 120. In this particular example, the
flexible, fibrous composite 110 is square; however, it need not be
square in order to achieve a folding transformation. The grains 130
are applied so that they create equal forces in both directions,
leading to a configuration that is bi-stable. The flexible, fibrous
composite 110 is square; however, it need not be square in order to
achieve a folding transformation. The bi-stable configuration is
thus a subset of the curve configuration illustrated in FIG. 2B.
For example, a curve can be created that curls from tip to tip,
rather than edge to edge like in 2B. The configuration can be
bi-stable if the flexible, fibrous composite is square, which
results in equal forces in opposite directions.
FIG. 2G shows a curve transformation. Parallel grains 130 of the
added material are orthogonal to an axis of the fiber 115a of the
flexible, flexible, fibrous composite, and coaxial with an axis of
the other fiber 115b. The grain 130 of the added material is
oriented at a 45.degree. angle relative to its own boundary 135 and
relative to the boundary 120 of the flexible, fibrous composite.
The length of a boundary 135 of the added material 130 is shorter
than the length of two different boundaries 120 of the flexible,
fibrous composite. The fibers 115a and 115b of the flexible,
fibrous composite are oriented at a 45.degree. angle relative to
its own boundary 120. In this particular example, the added
material is applied across a diagonal of the flexible, fibrous
composite 110, yielding the illustrated transformation.
Triaxial Weave Patterns and Oriented, Added Material
Unique orientations of the grain of the added material relative to
the axis of the flexible, fibrous substrate can yield different
transformation upon exposure to an external stimulus. Conceptually,
two features define the relationship between a biaxial flexible,
fibrous composite and the added material. First is the relationship
of the grain pattern of the added material to an axis of a fiber of
the flexible, fibrous composite. The triaxial weave pattern has
fibers along three axes. Typically, the grain pattern of the added
material will be coaxial with one of the axes, though it can be at
an angle as well. Second is the orientation of the grain of the
added material relative to a boundary of the flexible, fibrous
composite. When the grain pattern of the added material is coaxial
with one of the axes, the orientation can be 0.degree., 60.degree.,
or 120.degree. relative to a boundary of the flexible, fibrous
composite. Third is the length of a boundary of the added material
in relation to the length of a boundary of the flexible, fibrous
composite. The length of a boundary of the added material can be
the same length as the length of a boundary of the flexible,
fibrous composite. Alternatively, the length of a boundary of the
added material can be shorter than a boundary condition of the
flexible, fibrous composite. Fourth is the orientation of the
fibers of the flexible, fibrous composite relative to a boundary of
the flexible, fibrous composite. Typically, the fibers of the
flexible, fibrous composite are angled at 60.degree. and
120.degree. relative to a boundary of the flexible, fibrous
composite, though other angles are possible as well. As another
optional fifth condition, the added material can be printed on
opposing sides of the flexible, fibrous composite.
FIGS. 3A-C show three different types transformations that can be
created. In general, FIGS. 3A-C show the relative orientation of a
flexible, fibrous composite and the added material that is coupled
to it. The relationship between the two features described in the
preceding paragraph and the embodiments of FIGS. 3A-C are
summarized in Table 2.
TABLE-US-00002 TABLE 2 Features of biaxial flexible, fibrous
composite and added material illustrated in FIGS. 3A-C. 3. Length
of a 1. Relationship of 2. Orientation of boundary of the 4.
Orientation of the grain pattern the grain of the added material
the fibers of the of added material added material in relation to
flexible, fibrous to an axis of a relative to a the length of a
composite relative fiber of the boundary of the boundary of the to
a boundary of the FIG. and flexible, fibrous flexible, fibrous
flexible, fibrous flexible, fibrous Transformation composite
composite composite composite 3A: Curve Orthogonal 0.degree. to a
boundary Same length 60.degree. and 120.degree. 3B: Curve
Orthogonal 60.degree. to a boundary Same length 60.degree. and
120.degree. 3C: Curve Orthogonal 120.degree. to a boundary Same
length 60.degree. and 120.degree.
FIGS. 3A-C show flexible fibrous composites having a triaxial weave
pattern. In each of FIGS. 3A-C, the added material 130 is applied
along an axis 117a,b,c of one of the fibers of the flexible,
fibrous composite 110. Thus, each of the transformations in FIGS.
3A-C yields a similar transformation, though along a different
axis.
Uniaxial Weave Patterns and Oriented, Added Material
Unique orientations of the grain of the added material relative to
the axis of the flexible, fibrous substrate can yield different
transformation upon exposure to an external stimulus. Conceptually,
two features define the relationship between a biaxial flexible,
fibrous composite and the added material. First is the orientation
of the fibers of the flexible, fibrous composite to a boundary of
the flexible, fibrous composite. Since the uniaxial weave pattern
has fibers along one axis, typically the fibers are oriented
orthogonally to a boundary of the flexible, fibrous composite.
Second is the orientation of the grain of the added material
relative to a boundary of the flexible, fibrous composite. The
grain can be orthogonal to a boundary of the added material,
parallel to a boundary of the added material, or oriented at an
angle, such as a 45.degree. angle, relative to a boundary of the
added material. Third is the length of a boundary of the added
material in relation to the length of a boundary of the flexible,
fibrous composite. The length of a boundary of the added material
can be the same length as the length of a boundary of the flexible,
fibrous composite. Alternatively, the length of a boundary of the
added material can be shorter than a boundary condition of the
flexible, fibrous composite. Fourth is the orientation of the
fibers of the flexible, fibrous composite relative to a boundary of
the flexible, fibrous composite. Typically, the fibers of the
flexible, fibrous composite are orthogonal to one boundary (and
thus parallel to another) of the flexible, fibrous composite,
though other angles are possible as well. As another optional fifth
condition, the added material can be printed on opposing sides of
the flexible, fibrous composite.
FIGS. 4A-C show three different types transformations that can be
created. In general, FIGS. 4A-C show the relative orientation of a
flexible, fibrous composite and the added material that is coupled
to it. In each of FIGS. 4A-C, the added material 138 is applied
along an axis 118 of the fibers of the flexible, fibrous composite
110. The relationship between the two features described in the
preceding paragraph and the embodiments of FIGS. 4A-C are
summarized in Table 3.
TABLE-US-00003 TABLE 3 Features of biaxial flexible, fibrous
composite and added material illustrated in FIGS. 3A-C. 1.
Orientation of 3. Length of a the fibers of the 2. Orientation of
boundary of the 4. Orientation of flexible, fibrous the grain of
the added material the fibers of the composite added material in
relation to flexible, fibrous relative to a relative to a the
length of a composite relative boundary of the boundary of a
boundary of the to a boundary of the FIG. and flexible, fibrous
flexible, fibrous flexible, fibrous flexible, fibrous
Transformation composite composite composite composite 4A: Curve
Orthogonal 0.degree. to a boundary Same length Orthogonal 4B: Curve
Orthogonal Orthogonal to a Same length Orthogonal boundary 4C:
Bi-stable Orthogonal 45.degree. to a boundary Same length
Orthogonal
FIGS. 4A-C show flexible, fibrous composites having a uniaxial
weave pattern. In each of FIGS. 4A-C, the added material 130 is
applied to the flexible, fibrous composite. The flexible, uniaxial
fibrous composite has fibers 118 oriented in parallel strips.
Flexible, Fibrous Composites
A variety of composites are suitable for use as a flexible, fibrous
composite. One example is carbon fiber. Other examples include
glass fiber, basalt fiber, liquid crystal polymers/fibers, and
hybrids thereof. In general, the flexible, fibrous composites
described herein have different performance characteristics. For
example, some are more flexible than others, and some have more
tensile strength than others. Generally, the weave patterns of the
flexible, fibrous composite remain similar. The amount and rate of
transformation can vary depending on the type of materials and the
number of fibers. Thus, thickness and width can be adjusted to
achieve the proper contractive force to cause a shape change in
view of the coefficient of thermal expansion of the flexible,
fibrous composite and the added material. The greater the
difference in the coefficient of thermal expansion, the greater the
transformation effect. Polymer melt shrinkage and changes in the
coefficient of thermal expansion can also influence magnitude of
the transformation. For example, if the flexible, fibrous composite
is a nylon fiber composite, and the added material is nylon, the
difference in the coefficient of thermal expansion is very small,
and so is the transformation. As another example, a flexible,
fibrous composite that is a hybrid of carbon fiber and high
molecular weight polypropylene was used as a substrate for nylon as
an added material. The resulting product provided a smaller angle
of curvature (e.g., a smaller amount of transformation) compared to
examples where the flexible, fibrous composite is carbon fiber
alone. Thus, the general principles described herein remain
applicable, but the magnitude of the transformation can vary
depending on the materials chosen.
Added Materials
A variety of materials are suitable for use as an added material.
The flexible, fibrous composite and the added materials typically
have different rates of expansion and/or contraction in response to
an external stimulus. As one particular example, the added material
contracts more than the flexible, fibrous composite when cooled.
Some examples of added materials include nylon, biaxially-oriented
polyethylene terephthalate (BoPET, and available as MYLAR),
polypropylene, and hydrogels.
A useful characteristic of a hydrogel is its percentage of
expansion. For example, a hydrogel can expand 150% upon exposure to
water. This expansion can cause the flexible, fibrous composite to
curl such that the hydrogel is on the outside radius of curvature.
Other important characteristics of a hydrogel are whether it is
reversible (e.g., whether the hydrogel returns to its original
shape), how long it takes to swell and then return to its original
shape (e.g., dry out), and whether it deteriorates after repeated
use. Examples of suitable swelling hydrogels are well-known in the
art.
Another type of added material that is suitable for use in making a
self-transforming structure is a UV-curable polymer. Examples of
suitable polymers include those available from commercial 3D
printing companies. These UV-curable polymers can be applied by
3D-printing. Typically, they are applied as uncured monomers, which
are cured upon exposure to UV light.
Methods of Making Self-Transforming Structures
The added material is applied with its grains in an orientation
relative to fibers of the flexible, fibrous composite in a variety
of manners. In one embodiment, the added material is applied to the
flexible, fibrous composite by additive manufacturing, also
referred to as 3D printing. Additive manufacturing is a
particularly useful technology because it can be used to apply the
added material in a precisely oriented arrangement, thereby
allowing the added material to be patterned relative to the weave
pattern of the flexible, fibrous composite. For example, nylon can
be applied by an additive manufacturing process. Hydrogels are
typically applied by either an additive manufacturing or a
lamination procedure. In order to apply the added material to the
flexible, fibrous composite by 3D printing, a printing pattern for
the added material is designed (e.g., the printing patterns
illustrated in the figures, such as FIG. 2A-G, 3A-C, or 4A-C). The
carbon fiber is then placed in the printer in the appropriate
orientation. If necessary, the printer is calibrated. Printing
parameters, such as the height and thickness of the printing, are
specified. Finally, printing is commenced.
In some instances, the added material can be adhered to the
flexible, fibrous composite by a lamination procedure, which can be
a fast and consistent means for applying the added material to the
flexible, fibrous composite. In some of the Examples below, the
lamination was performed with a T-shirt press, though other means
for lamination are known in the art. In order to apply the added
material to the flexible, fibrous composite by lamination, the
added material is placed onto the flexible, fibrous composite, and
then lamination is commenced.
Additionally, reversible and non-reversible conditions for forming
in a fabrication process versus and active transition for movement
in a self-transforming structure can be encoded in the printing
pattern. For example, a sheet of flexible, fibrous composite with
secondary material can be designed to self-transform into a
predicted shape after being subjected to an external stimulus. This
eliminates the step of molding, tooling or other manual methods of
forming composite structures.
External Stimuli
A variety of different external stimuli can be used to cause shape
transformation. Typically, these external stimuli can also cause
expansion or contraction in response to temperature changes. For
example, lasers can be used to apply localized heating. As another
example, an infrared heat lamp can be used to provide heat.
Electrical resistive heating can also be used to provide heating,
such as through the use of a Nichrome wire or a flexible heat
pad.
As another example, electroactive polymers can be used.
Electroactive polymers can exhibit a change in size or shape in
response to an electric field.
As another example, ultraviolet (UV) radiation can be used to cure
UV-curable polymers, which typically contact during
cross-linking.
EXEMPLIFICATION
Example 1
Width of Added Material and Angle of Self-Transformation
Nylon 618 was applied to a Carbitex A324 flexible, fibrous
composite according to the pattern of FIG. 2A.
Table 4 lists measured angles of transformation that were observed
using different widths for the Nylon grains. The angles were
measured at room temperature.
TABLE-US-00004 TABLE 4 Relationship between width (b) of grains of
the added material and angle of transformation (a). Width (b) 3 mm
9 mm 18 mm 21 mm Angle (a) 15.00.degree. 44.33.degree.
63.67.degree. 97.67.degree.
As shown in Table 4, applying grains of the Nylon having different
widths can result in different angles of transformation upon
exposure to an external stimulus.
Example 2
Lamination Temperature and Grain Width
FIG. 5 is an annotated photograph of the experimental setup. Three
4''.times.4'' A324 carbon fiber samples (Carbitex LLC, Kennewick,
Wash., USA) were laminated with nylon strips having three different
widths. The Carbitex A324 product is biaxial and has fibers that
intersect at 90 degree angles. The weave pattern name is a
2.times.2 twill, where 2.times.2 refers to two over and two under
in both directions of the fiber bundles. Strips one and four: 1
inch wide; strips two and five: 2 inches wide; strips three and
six: 3 inches wide. Each of the three strips was applied to the
A324 carbon fiber in accordance with the pattern shown in FIG.
2D.
Laminating temperatures: 280.degree. F. and 400.degree. F.
Laminating pressure: one inch nylon strip: 162.5 psi; two inch
nylon strip: 81 psi; three inch nylon strip: 54 psi.
Lamination time: 300 seconds
The laminating was conducted in a T-shirt press 500 (Stahl's
Hotronix Thermal Transfer Press, Model #STX11) having a heated
platen 510. The T-shirt press was further instrumented in order to
accurately apply pressure with an Omega digital read out Model
DP25B-S-A and a 0-500 lb LeBow Load cell model number 3132-101. To
calculate the pressure, the force of the T-shirt press was divided
by the area of the lamination area of the subtracted to be bonded.
Release paper 520 is placed on both sides of the carbon fiber 530
and nylon 540 in order to facilitate release from the pressing
machine. Silicone 550 was used as a base.
FIGS. 6A-C and 7A-C are photographs showing the results of the
experiment. FIGS. 6A-C show the transformation of the 1 inch, 2
inch, and 3 inch nylon strips at 280.degree. F. FIGS. 7A-C show the
transformation of the 1 inch, 2 inch, and 3 inch nylon strips at
400.degree. F. FIGS. 7A-C are also referred to as 25% Strip, 50%
Strip, and 75% Strip, respectively, which refers to the percentage
of the width of the sample having Nylon across it. For a
4''.times.4'' square, a 1'' wide strip is referred to as 25% Strip;
a 2'' wide strip is referred to as 50% Strip; and a 3'' wide strip
is referred to as 75% Strip. The results are shown in Table 5:
TABLE-US-00005 TABLE 5 Observed transformation Temperature Strip
width Pressing duration Curvature (.degree. F.) (inches) (seconds)
(degrees) Strip 1 280 1 300 28 Strip 2 280 2 300 53 Strip 3 280 3
300 66 Strip 4 400 1 300 41 Strip 5 400 2 300 63 Strip 6 400 3 300
101
Observations: 1) Lamination pressure impacts nylon wet out to
Carbitex A324. As the shear force increases during the lamination
process, low lamination pressure or low wet out of the bonded
surface can reduce the amount bonded surface area, thereby allowing
the lamination to decouple. Thus, sufficient lamination pressure is
necessary to ensure adequate bonding between the nylon and carbon
fiber. The minimum lamination pressure depends on the viscosity of
the added material that is being bonded. As tested, a pressure of
54 psi appears sufficient to ensure appropriate lamination. 2)
Angle of curl depends on lamination temperature; angle of curl
depends on lamination width. 3) Zero degree angle of curl is equal
to the lamination temperature. If the lamination occurs at ambient
temperature, the lamination is stable and no curling will occur
when the temperature remains at ambient temperature. If the ambient
temperature lamination is subsequently heated, the expansion
differential will cause a curl. Likewise, when the flexible,
fibrous composite is laminated at elevated temperatures, as shown
in Table 4, the contraction differential of the flexible, fibrous
composite and the added material will cause curling at ambient
temperature. Similarly, zero degree curling will be occur at the
lamination temperature. For example, if lamination occurs at
280.degree. F., there will be 28 degree curvature at ambient
temperature. However, if reheated to 280.degree. F., the angle of
curvature will be zero.
Without wishing to be bound by theory, it is believed that change
in length can be modeled according to Formula (I):
.DELTA.L=.alpha.*L.sub.0*(T-T.sub.0) (I)
.alpha.=coefficient of thermal expansion (CTE)
L.sub.0=original length (e.g., of nylon)
T.sub.0=initial temperature
T=temperature
For nylon, .alpha. is between approximately 4.times.10.sup.-5 and
5.5.times.10.sup.-5 in/in/.degree. F.
FIGS. 8A and 8B are illustrations showing nylon coupled to a carbon
fiber. FIG. 8A shows nylon adjacent to carbon fiber prior to
lamination. FIG. 8B shows nylon coupled to carbon fiber after
lamination and the shape transformation that has occurred. Table 6
describes calculated changes in Nylon based on the coefficient of
thermal expansion a that temperature differential.
TABLE-US-00006 TABLE 6 Calculated changes in length of Nylon based
on the coefficient of thermal expansion at that temperature
differential L.sub.0 CTE T.sub.0 T L (in) (in/in/.degree. F.)
(.degree. F.) (.degree. F.) (in) 1 4.00E-05 75 280 0.0082 2
4.00E-05 75 280 0.0164 3 4.00E-05 75 280 0.0246 1 4.00E-05 75 400
0.013 2 4.00E-05 75 400 0.026 3 4.00E-05 75 400 0.039
Example 3
Self-Transformation in Response to Temperature Change
FIG. 9 is an annotated photograph of an experimental setup for
measuring self-transformation in response to temperature changes.
In both FIG. 9 and FIGS. 10A-I, nylon was laminated onto carbon
fiber according to the pattern illustrated in FIG. 2D.
An Oster convection oven 910 (Model No. TSSTTVDGXL) was used to
heat the self-transforming structure 920. An aluminum block 930 was
used to hold down one end of the self-transforming structure 920. A
fine wire thermocouple 940 was used to measure temperature, and a
protractor 950 was used to measure the angle of transformation.
Temperature values were measured during heating to correlate the
angle of movement to temperature increase. The results are show in
FIGS. 10A-I, which is a series of time-lapse photographs. The
measured values are provided in Table 7, and FIG. 11 is a graph
showing the measured angle vs. temperature change
(y=-0.3461x+47.982; R.sup.2=0.9931).
TABLE-US-00007 TABLE 7 Measured angles of transformation Time
Temperature Angle Corresponding (mm:ss) (.degree. F.) (.degree.)
FIG. 0:00 83 37 10A 1:00 119 33 10B 2:00 150 24 10C 3:00 187 19 10D
4:00 221 12 10E 5:00 240 9 10F 7:00 246 7 10G 10:12 261 3 10H 10:32
273 1 10I
Example 4
Twisting and Folding Self-Transforming Structures
A twisting and a folding transformation are shown in FIGS. 12A-B
and 13A-B.
FIG. 12A is a series of time-lapsed photographs showing a twisting
transformation. FIG. 12B shows superimposed photos of a time-lapsed
twisting transformation. In this prototype, the printed nylon
filament was extruded onto Carbitex A324 flexible, fibrous
composite at a temperature of 220.degree. C. to 240.degree. C.
while the heated bed temperature was at 50.degree. C. The width of
the printed grain pattern was approximately 20 mm, printed in a
similar pattern with relation to the grain of the flexible carbon
fiber as shown in FIG. 2C. The first layer height was printed at
0.6 mm above the carbon surface. The second layer was printed at
0.3 mm above the first. The printed grains were spaced at 0.4 mm
offset from one another. After printing, the prototype was heated
with ambient heat from a heat bed set to 400.degree. C. for about
10 seconds.
FIG. 13A is a series of time-lapsed photographs showing a folding
transformation. FIG. 13B shows superimposed photos of a time-lapsed
folding transformation. In this prototype, the printed nylon
filament was extruded onto Carbitex A324 flexible, fibrous
composite at a temperature of 220.degree. C. to 240.degree. C.
while the heated bed temperature was at 50.degree. C. The width of
the printed grain pattern was approximately 20 mm, printed in a
similar pattern with relation to the grain of the flexible carbon
fiber as shown in FIG. 2A. The first layer height was printed at
0.6 mm above the carbon surface. The second layer was printed at
0.3 mm above the first. The printed grains were spaced at 0.4 mm
offset from one another. After printing, the prototype was heated
with ambient heat from a heat bed set to 400.degree. C. for about
10 seconds.
Example 5
Use of Self-Transforming Structure in an Airplane Engine
FIG. 14 is a series of time-lapsed photographs showing a folding
transformation superimposed on top of one another. In this
prototype, the printed nylon filament was extruded at a temperature
of 220.degree. C. to 240.degree. C. while the heated bed
temperature was at 50.degree. C. The width of the printed grain
pattern was approximately 20 mm, printed in a similar pattern with
relation to the grain of the flexible carbon fiber as shown in FIG.
2A. The first layer height was printed at 0.6 mm above the carbon
surface. The second layer was printed at 0.3 mm above the first.
The printed grains were spaced at 0.4 mm offset from one another.
After printing, the prototype was heated with ambient heat from a
heat bed set to 400.degree. C. for .about.10 seconds. This
embodiment can be used to provide adaptive control of fluid flow in
response to temperature changes.
Example 6
Self-Transforming Structure Formed of Flexible, Fibrous Composite
Having a Triaxial Weave
FIG. 15 is an example of a triaxial weave of T700 carbon fiber
(Gernitex; Product No. TXD-20-T700-120) with 22 mm wide strips of
fiber woven in 0 degree, +60 degree and -60 degree orientation. The
Gernitex T700 carbon fiber has an areal density of 120 grams per
square meter areal. The laminated sheet on top of the weave can be
placed in-line with the fiber orientation at 0, 120 or 60 degree to
achieve a curve, 2 curve, or 3 curve type behavior
respectively.
Example 7
Self-Transforming Structure Formed of Flexible, Fibrous Composite
Having a Uniaxial Weave
FIG. 16 is an example of a uniaxial weave orientation of carbon
fiber. The pattern on top of the weave can be placed in-line with
the fiber (top) or orientated at 90.degree. relative to the fiber
orientation (bottom) to achieve a 1-curve or 2-curve type behavior,
respectively.
Example 8
Self-Transforming Structures with Triaxial Flexible, Fibrous
Composite
FIGS. 17A and 17B are photographs of a self-transforming
structures. The grain direction of the added material is indicated
with arrows and is patterned as illustrated in FIG. 3A.
Example 9
Self-Transforming Structures with Biaxial Flexible, Fibrous
Composite
FIGS. 18A-D are photographs of self-transforming structures. For
each photograph, the flexible, fibrous composite is Carbitex A324,
and the added material is Nylon 618. For each photograph, the added
material was printed onto the flexible, fibrous composite using a
Fused Deposition Modeling (FDM) 3D printer. Each of the photographs
was taken at a room temperature. FIG. 18A is a photograph of a
curve transformation, in which the added material was printed onto
the flexible, fibrous composite according to FIG. 2B. FIG. 18B is a
photograph of a fold transformation, in which the added material
was printed onto the flexible, fibrous composite according to FIG.
2A. FIG. 18C is a wave transformation, in which the added material
was printed onto the flexible, fibrous composite according to FIG.
2E. FIG. 18D is a spiral transformation, in which the added
material was printed onto the flexible, fibrous composite according
to FIG. 2D.
INCORPORATION BY REFERENCE AND EQUIVALENTS
The teachings of all patents, published applications and references
cited herein are incorporated by reference in their entirety.
While this invention has been particularly shown and described with
references to example embodiments thereof, it will be understood by
those skilled in the art that various changes in form and details
may be made therein without departing from the scope of the
invention encompassed by the appended claims.
* * * * *
References