U.S. patent application number 15/161770 was filed with the patent office on 2016-11-24 for active self-transformable textiles.
The applicant listed for this patent is Massachusetts lnstitute of Technology. Invention is credited to Christophe Guberan, Athina Papadopoulou, Skylar JE Tibbits.
Application Number | 20160340826 15/161770 |
Document ID | / |
Family ID | 57324565 |
Filed Date | 2016-11-24 |
United States Patent
Application |
20160340826 |
Kind Code |
A1 |
Tibbits; Skylar JE ; et
al. |
November 24, 2016 |
ACTIVE SELF-TRANSFORMABLE TEXTILES
Abstract
An active self-transformable material comprising a flexible base
material with an active material disposed on or within the flexible
base material in a specific pattern. More particularly, the active
material and the flexible base material differ in properties such
that the active material is reactive to an external stimulus
trigger that to cause an automatic transformation of the active
self-transformable material into a predetermined 3-dimensional
transformed shape.
Inventors: |
Tibbits; Skylar JE; (Boston,
MA) ; Papadopoulou; Athina; (Cambridge, MA) ;
Guberan; Christophe; (LaPraz, CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Massachusetts lnstitute of Technology |
Cambridge |
MA |
US |
|
|
Family ID: |
57324565 |
Appl. No.: |
15/161770 |
Filed: |
May 23, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62165425 |
May 22, 2015 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 27/32 20130101;
B32B 2437/00 20130101; B32B 5/02 20130101; B32B 2270/00 20130101;
D06M 15/19 20130101; B32B 3/10 20130101; B32B 2262/062 20130101;
D06M 23/16 20130101; B32B 5/024 20130101; B32B 2262/08 20130101;
B32B 2262/0207 20130101; D06M 15/227 20130101; B32B 27/12 20130101;
B32B 2262/023 20130101; B32B 2307/75 20130101; B32B 2307/546
20130101; B32B 27/36 20130101; B32B 2262/0292 20130101; D06Q 1/08
20130101; B32B 7/12 20130101; B32B 5/18 20130101; D06M 15/507
20130101; B32B 2262/0276 20130101; D06Q 1/00 20130101; B32B 9/025
20130101; B32B 25/00 20130101; B32B 27/304 20130101; D06M 15/256
20130101; B32B 2307/732 20130101; B32B 2601/00 20130101; B32B 5/026
20130101; B32B 2262/0215 20130101; B32B 2605/003 20130101 |
International
Class: |
D06M 15/19 20060101
D06M015/19 |
Claims
1. An active self-transformable material comprising: a flexible
base material; and an active material disposed on the flexible base
material in a predetermined pattern to form a combined structure,
the combined structure having a natural shape, wherein the active
material is reactive to an external stimulus trigger, and the
flexible base material is non-reactive to the external stimulus
trigger, minimally reactive to the external stimulus trigger, or
reactive to the external stimulus trigger differently than the
active material, and wherein exposure of at least a portion of the
predetermined pattern of the active material to the external
stimulus trigger changes the shape of the combined structure from
the natural shape into a predetermined 3-dimensional transformed
shape.
2. The active self-transformable material of claim 1, wherein the
natural shape of the combined structure is a shape of the combined
structure absent an external stimulus trigger.
3. The active self-transformable material of claim 1, wherein the
flexible base material is selected from stretchable and
non-stretchable textiles, elastomeric materials, plastics, rubber,
leather, animal skin materials, vegan alternatives to animal skin
materials, and sheet foam.
4. The active self-transformable material of claim 1, wherein the
flexible base material is a textile selected from the group
consisting of cotton, neoprene, jersey, vinyl, velvet, brocade,
silk, polyesters, wool, linen, mesh, and polyester-polyurethane
copolymers, including elastane, and spandex.
5. The active self-transformable material of claim 1, wherein the
active material is a material activated by exposure to temperature
change, exposure to light change, exposure to solvents, exposure to
moisture, exposure to energy, including electrical energy, exposure
to infrared light, exposure to visible light, and exposure to
ultraviolet light.
6. The active self-transformable material of claim 1, wherein the
active material is a material selected from hydrogels, plastics,
polyethylene (PE), polyethylene terephthalate (PET), polyvinylidene
fluoride (PVDF), thermoplastic polymers, and combinations
thereof.
7. The active self-transformable material of claim 1, wherein the
active material is reactive to the external stimulus trigger by
swelling or shrinking.
8. The active self-transformable material of claim 1, wherein the
active material has a thermal expansion modulus that causes the
active material to shrink or swell upon exposure to a temperature
change.
9. The active self-transformable material of claim 1, wherein the
change in the shape of the combined structure from the natural
shape into a predetermined 3-dimensional transformed shape is a
reversible change.
10. The active self-transformable material of claim 1, wherein the
change in the shape of the combined structure from the natural
shape into a predetermined 3-dimensional transformed shape is an
irreversible change.
11. The active self-transformable material of claim 1, wherein the
flexible base material is in the form of a generally flat and
flexible material having a plurality of flaps disposed therein,
wherein the active material is disposed on the plurality of flaps
in such a manner that exposing the active material to the external
stimulus trigger causes the flaps to lift and form a plurality of
air vents.
12. A method of forming an active self-transformable material
comprising: providing a flexible base material; and disposing an
active material on one or more surfaces of the flexible base
material or within the flexible base material in a specific pattern
to form a combined structure having a natural shape, wherein the
active material is a material that is reactive to exposure to an
external stimulus trigger, wherein the flexible base material is
non-reactive to the external stimulus trigger, minimally reactive
to the external stimulus trigger, or reactive to the external
stimulus trigger differently than the active material, and wherein
exposure of at least a portion of the specific pattern of the
active material to the external stimulus trigger changes the shape
of the combined structure from the natural shape into a
predetermined 3-dimensional transformed shape.
13. The method claim 12, wherein the natural shape of the combined
structure is a shape of the combined structure absent exposure to
the external stimulus trigger.
14. The method of claim 12, wherein disposing the specific pattern
of the active material onto the flexible base material comprises 3D
printing the active material, laminating or adhering the specific
pattern of the active material to flexible base material, or
knitting, weaving, stitching, or injecting the active material in
the predetermined pattern onto or within the flexible base
material.
15. The method of claim 12, wherein the specific pattern further
includes particular heights and widths of the active material along
the pattern.
16. The method of claim 12, further comprising tailoring one or
more properties of the flexible base material and the active
material to achieve the predetermined transformed 3-dimensional
shape, the one or more properties being selected from a composition
of the flexible base material, composition of the active material,
a particular shape of the flexible base material, a thickness of
the flexible base material, a stiffness of the flexible base
material, a flexibility of the flexible base material, a
directionality of the flexible base material, a thickness of the
flexible base material, a thickness pattern of the active material,
a width pattern of the active material, an overall design pattern
of the active material, an amount of the active material, and a
difference between one or more properties of flexible base material
and the active material.
17. The method of claim 12, wherein the external stimulus trigger
is selected from one or more solvents, a temperature change,
energy, a pressure change, a lighting change, moisture infrared
light, visible light, and ultraviolet light, and combinations
thereof.
18. The method of claim 12, wherein the flexible base material is a
material selected from stretchable and non-stretchable textiles,
elastomeric materials, plastics, rubber, leather, animal skin
materials, vegan alternatives to animal skin materials, and sheet
foam.
19. The method claim 12, wherein the flexible base material is a
stretchable or non-stretchable textile selected from the group
consisting of cotton, neoprene, jersey, vinyl, velvet, brocade,
silk, polyesters, wool, linen, mesh, and polyester-polyurethane
copolymers, including elastane, and spandex.
20. The method of claim 12, wherein the active material is a
material selected from materials activated by exposure to
temperature change, exposure to light change, exposure to solvents,
exposure to moisture, exposure to energy, including electrical
energy, exposure to infrared light, exposure to visible light, and
exposure to ultraviolet light.
21. The method of claim 12, wherein the active material is a
material selected from hydrogels, plastics, polyethylene (PE),
polyethylene terephthalate (PET), polyvinylidene fluoride (PVDF),
thermoplastic polymers, and combinations thereof.
22. The method of claim 12, wherein the active material is reactive
to the external stimulus trigger by swelling or shrinking.
23. The method of claim 12, wherein the active material has a
thermal expansion modulus that causes the active material to shrink
or swell upon exposure to a temperature change.
24. The method of claim 12, wherein the change in the shape of the
combined structure from the natural shape into the predetermined
3-dimensional transformed shape is a reversible change.
25. The method of claim 12, wherein the change in the shape of the
combined structure from the natural shape into the predetermined
3-dimensional transformed shape is an irreversible change.
26. A method of forming a predetermined 3-dimensional manufactured
shape comprising: providing a flexible base material; disposing an
active material on one or more surfaces of the flexible base
material or within the flexible base material in a specific pattern
to form a combined structure having a natural shape, wherein the
active material is a material that is reactive to exposure to an
external stimulus trigger, and wherein the flexible base material
is non-reactive to the external stimulus trigger, minimally
reactive to the external stimulus trigger, or reactive to the
external stimulus trigger differently than the active material; and
exposing at least a portion of the specific pattern of the active
material to the external stimulus trigger to cause a change in the
shape of the combined structure from the natural shape into the
predetermined 3-dimensional manufactured shape.
27. The method of claim 26, wherein exposing at least a portion of
the specific pattern of the active material to the external
stimulus trigger comprises exposing only a portion of the specific
pattern to the external stimulus trigger to achieve a localized
change in the shape of the combined structure.
28. The method of claim 26, wherein disposing the specific pattern
of the active material onto the flexible base material comprises 3D
printing the active material, laminating or adhering the specific
pattern of the active material to flexible base material, or
knitting, weaving, stitching, or injecting the active material in
the predetermined pattern onto or within the flexible base
material.
29. The method of claim 26, further comprising tailoring one or
more properties of the flexible base material and the active
material to achieve the predetermined transformed 3-dimensional
shape, the one or more properties being selected from a composition
of the flexible base material, composition of the active material,
a particular shape of the flexible base material, a thickness of
the flexible base material, a stiffness of the flexible base
material, a flexibility of the flexible base material, a
directionality of the flexible base material, a thickness of the
flexible base material, a thickness pattern of the active material,
a width pattern of the active material, an overall design pattern
of the active material, an amount of the active material, and a
difference between one or more properties of flexible base material
and the active material.
30. The method of claim 26, wherein the external stimulus trigger
is selected from one or more solvents, a temperature change,
energy, a pressure change, a lighting change, moisture infrared
light, visible light, and ultraviolet light, and combinations
thereof.
31. The method of claim 26, wherein the flexible base material is a
material selected from stretchable and non-stretchable textiles,
elastomeric materials, plastics, rubber, leather, animal skin
materials, vegan alternatives to animal skin materials, and sheet
foam.
32. The method claim 26, wherein the flexible base material is a
stretchable or non-stretchable textile selected from the group
consisting of cotton, neoprene, jersey, vinyl, velvet, brocade,
silk, polyesters, wool, linen, mesh, and polyester-polyurethane
copolymers, including elastane, and spandex.
33. The method of claim 26, wherein the active material is a
material selected from materials activated by exposure to
temperature change, exposure to light change, exposure to solvents,
exposure to moisture, exposure to energy, including electrical
energy, exposure to infrared light, exposure to visible light, and
exposure to ultraviolet light.
34. The method of claim 26, wherein the active material is a
material selected from hydrogels, plastics, polyethylene (PE),
polyethylene terephthalate (PET), polyvinylidene fluoride (PVDF),
thermoplastic polymers, and combinations thereof.
35. The method of claim 26, wherein the active material is reactive
to the external stimulus trigger by swelling or shrinking.
36. The method of claim 26, wherein the active material has a
thermal expansion modulus that causes the active material to shrink
or swell upon exposure to a temperature change.
37. The method of claim 26, wherein the change in the shape of the
combined structure from the natural shape into the predetermined
3-dimensional transformed shape is a reversible change.
38. The method of claim 26, wherein the change in the shape of the
combined structure from the natural shape into the predetermined
3-dimensional transformed shape is an irreversible change.
39. The method of claim 26 further comprising, before exposing at
least a portion of the specific pattern of the active material to
the external stimulus trigger forming the combined structure having
a natural shape into a first 3-dimensional structure, wherein
subsequent exposing at least a portion of the specific pattern of
the active material to the external stimulus trigger causes a
change in natural shape of the combined structure forming the first
3-dimensional structure into the predetermined 3-dimensional
manufactured shape.
40. The method of claim 39, wherein the flexible base material is
in the form of a generally flat and flexible material having a
plurality of flaps disposed therein, wherein the active material is
disposed on the plurality of flaps in such a manner that exposing
the active material to the external stimulus trigger causes the
flaps to lift and form a plurality of air vents, and wherein the
predetermined 3-dimensional manufactured shape is the first
3-dimensional structure with the plurality of air vents in a lifted
position.
41. The method of claim 40, wherein the external stimulus trigger
is a temperature change.
Description
RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/165,425, filed on May 22, 2015. The entire
teaching of the above application is incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to active self-transformable
materials. More particularly, the present invention relates to a
method for creating self-transformable materials by printing,
laminating, or otherwise disposing one or more active materials
onto and/or within a flexible base material to promote precise
shape transformations upon exposure of the active
self-transformable material to an external stimulus.
BACKGROUND OF THE INVENTION
[0003] Many industries require precisely shaped materials to meet
aesthetic and/or functional needs. While current manual and
automated methods and technologies may possibly meet these needs to
some extent, these methods and technologies are often complex,
require significant energy, precision and skill, and require
expensive tools and machinery to produce the desired intricate
shapes. In addition, current manufacturing technologies generally
provide a static product. In particular, current methods and
technologies typically involve the formation of parts and other
components having a fixed shape, and those individual components
are then assembled into more complex structures also having a fixed
shape. Thus, most products found in the marketplace take on a
single form, and that form does not change or adapt. In view of
these limitations, improvements are needed in the design and
manufacture of 3-dimensional shaped products in many industries. In
addition, it would be desirable to provide materials, clothing,
footwear, and other goods that are highly active rather than
static, so as to provide enhanced performance (e.g., breathability,
moisture control, temp control, dynamic compression, etc.).
[0004] For example, in sports and physical fitness, complex 3D
structures for sportswear and equipment are required from a
performance and aesthetic perspective. In addition, sportswear and
equipment that has a more customized fit and which can provide
compression, constraint, and/or protection where needed are in
demand. In the related world of fashion design, intricate patterns
using pleating and complex stitching details are often utilized.
When designing clothing, footwear and other accessories, the
materials must be formed into shapes having a complex curvature to
provide a variety of wearers with a proper fit. In particular,
footwear and leather goods are examples of products that rely on
industrial forming techniques to stretch and force materials around
a physical mold to achieve a complex curvature. The physical mold
imposes constraints on the possible number and complexity of the
end product given that a new mold is needed for each unique
product. These molds tend to be expensive, static and simple due to
their manufacture, which typically uses CNC-machining.
[0005] Interior design involves furniture and other products that
typically require manual assembly, molding, pleating, tufting,
knotting, complex stitching, and other intricate detailing
processes. Further, textile-based complex and 3-dimensional
interior partitions and other wall treatments are commonly used.
Manufacture of these goods often requires manual or automated
skilled and precise control for production, which increases the
time and energy needed to produce each item. This further drives up
the price of these products, relegating highly detailed products to
high-end markets or hand-craft couture spaces.
[0006] In the medical and health fields, compression garments with
various degrees of compression and tension across the body are
needed to help circulate blood flow in custom pathways and to
provide support.
[0007] Thus, it would be desirable to provide new materials and
methods which make it possible to more easily provide currently
manufactured complex 3D shaped materials, and to provide 3D shaped
materials that have not been previously attainable. In addition
customization of the manufactured 3D shapes, without increasing or
the complexity, skill, and time for producing custom products would
be highly desirable.
[0008] In addition, nearly every industry has long desired smarter
materials and robotic-like transformation--from apparel,
architecture, product design and manufacturing, to aerospace and
automotive industries. However, these capabilities have often
required expensive, error-prone and complex electromechanical
devices (e.g., motors, sensors, electronics), bulky components,
power consumption (e.g., batteries or electricity) and difficult
assembly processes. These constraints have made it challenging to
efficiently produce dynamic systems, higher-performing machines and
more adaptive products.
[0009] Further, while "smart" materials have been developed, which
can provide some sort of a dynamic structure, such materials are
often formed in fixed shapes and sizes. These materials must
subsequently be assembled into the necessary end product form,
typically using off the shelf (non-custom) parameters. These types
of smart materials are extremely expensive and are generally only
found in niche markets due to their cost. Further, using these
smart materials to provide a specific type of product having a
particular shape requires significant skill and time.
[0010] Thus, it would be desirable to provide new materials and
methods which make it possible to more easily provide currently
manufactured complex 3D shaped materials, and to provide 3D shaped
materials that have not been previously attainable. Further, it
would be desirable to provide such materials which are further
capable of dynamically changing their shape on demand, particularly
in response to an external trigger.
SUMMARY OF THE INVENTION
[0011] Embodiments of the present invention provide a novel
materiel, method of manufacture, and complex 3-dimensional
structures and active structures formed therefrom.
[0012] According to one aspect, the present invention provides an
active self-transformable material comprising a flexible base
material, and an active material disposed on the flexible base
material in a predetermined pattern to form a combined structure,
the combined structure having a natural shape. In particular, the
active material is reactive to an external stimulus trigger, and
the flexible base material is non-reactive to the external stimulus
trigger, minimally reactive to the external stimulus trigger, or
reactive to the external stimulus trigger differently than the
active material, wherein exposure of at least a portion of the
predetermined pattern of the active material to the external
stimulus trigger changes the shape of the combined structure from
the natural shape into a predetermined 3-dimensional transformed
shape.
[0013] According to various embodiments, the material can comprise
one or more of the following features. The natural shape of the
combined structure is a shape of the combined structure absent an
external stimulus trigger. The flexible base material is selected
from stretchable and non-stretchable textiles, elastomeric
materials, plastics, rubber, leather, animal skin materials, vegan
alternatives to animal skin materials, and sheet foam. The flexible
base material is a textile selected from the group consisting of
cotton, neoprene, jersey, vinyl, velvet, brocade, silk, polyesters,
wool, linen, mesh, and polyester-polyurethane copolymers, including
elastane, and spandex. The active material is a material activated
by exposure to temperature change, exposure to light change,
exposure to solvents, exposure to moisture, exposure to energy,
including electrical energy, exposure to infrared light, exposure
to visible light, and exposure to ultraviolet light. The active
material is a material selected from hydrogels, plastics,
polyethylene (PE), polyethylene terephthalate (PET), polyvinylidene
fluoride (PVDF), thermoplastic polymers, and combinations thereof.
The active material is reactive to the external stimulus trigger by
swelling or shrinking. The active material has a thermal expansion
modulus that causes the active material to shrink or swell upon
exposure to a temperature change. The change in the shape of the
combined structure from the natural shape into a predetermined
3-dimensional transformed shape is a reversible change. The change
in the shape of the combined structure from the natural shape into
a predetermined 3-dimensional transformed shape is an irreversible
change. The flexible base material is in the form of a generally
flat and flexible material having a plurality of flaps disposed
therein, wherein the active material is disposed on the plurality
of flaps in such a manner that exposing the active material to the
external stimulus trigger causes the flaps to lift and form a
plurality of air vents.
[0014] According to another aspect, the present invention provides
a method of forming an active self-transformable material
comprising providing a flexible base material, and disposing an
active material on one or more surfaces of the flexible base
material or within the flexible base material in a specific pattern
to form a combined structure having a natural shape, wherein the
active material is a material that is reactive to exposure to an
external stimulus trigger, wherein the flexible base material is
non-reactive to the external stimulus trigger, minimally reactive
to the external stimulus trigger, or reactive to the external
stimulus trigger differently than the active material, and wherein
exposure of at least a portion of the specific pattern of the
active material to the external stimulus trigger changes the shape
of the combined structure from the natural shape into a
predetermined 3-dimensional transformed shape.
[0015] According to various embodiments, the method can comprise
one or more of the following features. The natural shape of the
combined structure is a shape of the combined structure absent
exposure to the external stimulus trigger. Disposing the specific
pattern of the active material onto the flexible base material
comprises 3D printing the active material, laminating or adhering
the specific pattern of the active material to flexible base
material, or knitting, weaving, stitching, or injecting the active
material in the predetermined pattern onto or within the flexible
base material. The specific pattern further includes particular
heights and widths of the active material along the pattern. The
method further comprises tailoring one or more properties of the
flexible base material and the active material to achieve the
predetermined transformed 3-dimensional shape, the one or more
properties being selected from a composition of the flexible base
material, composition of the active material, a particular shape of
the flexible base material, a thickness of the flexible base
material, a stiffness of the flexible base material, a flexibility
of the flexible base material, a directionality of the flexible
base material, a thickness of the flexible base material, a
thickness pattern of the active material, a width pattern of the
active material, an overall design pattern of the active material,
an amount of the active material, and a difference between one or
more properties of flexible base material and the active material.
The external stimulus trigger is selected from one or more
solvents, a temperature change, energy, a pressure change, a
lighting change, moisture infrared light, visible light, and
ultraviolet light, and combinations thereof. The flexible base
material is a material selected from stretchable and
non-stretchable textiles, elastomeric materials, plastics, rubber,
leather, animal skin materials, vegan alternatives to animal skin
materials, and sheet foam. The flexible base material is a
stretchable or non-stretchable textile selected from the group
consisting of cotton, neoprene, jersey, vinyl, velvet, brocade,
silk, polyesters, wool, linen, mesh, and polyester-polyurethane
copolymers, including elastane, and spandex. The active material is
a material selected from materials activated by exposure to
temperature change, exposure to light change, exposure to solvents,
exposure to moisture, exposure to energy, including electrical
energy, exposure to infrared light, exposure to visible light, and
exposure to ultraviolet light. The active material is a material
selected from hydrogels, plastics, polyethylene (PE), polyethylene
terephthalate (PET), polyvinylidene fluoride (PVDF), thermoplastic
polymers, and combinations thereof. The active material is reactive
to the external stimulus trigger by swelling or shrinking. The
active material has a thermal expansion modulus that causes the
active material to shrink or swell upon exposure to a temperature
change. The change in the shape of the combined structure from the
natural shape into the predetermined 3-dimensional transformed
shape is a partially or fully reversible change. The change in the
shape of the combined structure from the natural shape into the
predetermined 3-dimensional transformed shape is an irreversible
change.
[0016] According to another aspect, the present invention provides
a method of forming a predetermined 3-dimensional manufactured
shape comprising providing a flexible base material, disposing an
active material on one or more surfaces of the flexible base
material or within the flexible base material in a specific pattern
to form a combined structure having a natural shape, wherein the
active material is a material that is reactive to exposure to an
external stimulus trigger, and wherein the flexible base material
is non-reactive to the external stimulus trigger, minimally
reactive to the external stimulus trigger, or reactive to the
external stimulus trigger differently than the active material, and
exposing at least a portion of the specific pattern of the active
material to the external stimulus trigger to cause a change in the
shape of the combined structure from the natural shape into the
predetermined 3-dimensional manufactured shape.
[0017] According to various embodiments, the method can include one
or more of the following features. Exposing at least a portion of
the specific pattern of the active material to the external
stimulus trigger comprises exposing only a portion of the specific
pattern to the external stimulus trigger to achieve a localized
change in the shape of the combined structure. Disposing the
specific pattern of the active material onto the flexible base
material comprises 3D printing the active material, laminating or
adhering the specific pattern of the active material to flexible
base material, or knitting, weaving, stitching, or injecting the
active material in the predetermined pattern onto or within the
flexible base material. The method further comprises tailoring one
or more properties of the flexible base material and the active
material to achieve the predetermined transformed 3-dimensional
shape, the one or more properties being selected from a composition
of the flexible base material, composition of the active material,
a particular shape of the flexible base material, a thickness of
the flexible base material, a stiffness of the flexible base
material, a flexibility of the flexible base material, a
directionality of the flexible base material, a thickness of the
flexible base material, a thickness pattern of the active material,
a width pattern of the active material, an overall design pattern
of the active material, an amount of the active material, and a
difference between one or more properties of flexible base material
and the active material. The external stimulus trigger is selected
from one or more solvents, a temperature change, energy, a pressure
change, a lighting change, moisture infrared light, visible light,
and ultraviolet light, and combinations thereof. The flexible base
material is a material selected from stretchable and
non-stretchable textiles, elastomeric materials, plastics, rubber,
leather, animal skin materials, vegan alternatives to animal skin
materials, and sheet foam. The flexible base material is a
stretchable or non-stretchable textile selected from the group
consisting of cotton, neoprene, jersey, vinyl, velvet, brocade,
silk, polyesters, wool, linen, mesh, and polyester-polyurethane
copolymers, including elastane, and spandex. The active material is
a material selected from materials activated by exposure to
temperature change, exposure to light change, exposure to solvents,
exposure to moisture, exposure to energy, including electrical
energy, exposure to infrared light, exposure to visible light, and
exposure to ultraviolet light. The active material is a material
selected from hydrogels, plastics, polyethylene (PE), polyethylene
terephthalate (PET), polyvinylidene fluoride (PVDF), thermoplastic
polymers, and combinations thereof. The active material is reactive
to the external stimulus trigger by swelling or shrinking. The
active material has a thermal expansion modulus that causes the
active material to shrink or swell upon exposure to a temperature
change. The change in the shape of the combined structure from the
natural shape into the predetermined 3-dimensional transformed
shape is a partially or fully reversible change. The change in the
shape of the combined structure from the natural shape into the
predetermined 3-dimensional transformed shape is an irreversible
change. The method further comprises, before exposing at least a
portion of the specific pattern of the active material to the
external stimulus trigger forming the combined structure having a
natural shape into a first 3-dimensional structure, wherein
subsequent exposing at least a portion of the specific pattern of
the active material to the external stimulus trigger causes a
change in natural shape of the combined structure forming the first
3-dimensional structure into the predetermined 3-dimensional
manufactured shape. The flexible base material is in the form of a
generally flat and flexible material having a plurality of flaps
disposed therein, wherein the active material is disposed on the
plurality of flaps in such a manner that exposing the active
material to the external stimulus trigger causes the flaps to lift
and form a plurality of air vents, and wherein the predetermined
3-dimensional manufactured shape is the first 3-dimensional
structure with the plurality of air vents in a lifted position. The
external stimulus trigger is a temperature change.
[0018] Other systems, methods and features of the present invention
will be or become apparent to one having ordinary skill in the art
upon examining the following drawings and detailed description. It
is intended that all such additional systems, methods, and features
be included in this description, be within the scope of the present
invention and protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings are included to provide a further
understanding of the invention, and are incorporated in and
constitute a part of this specification. The components in the
drawings are not necessarily to scale, emphasis instead being
placed upon clearly illustrating the principles of the present
invention. The drawings illustrate embodiments of the invention
and, together with the description, serve to explain the principals
of the invention.
[0020] FIGS. 1A-1C illustrate deposition of an active material onto
a flexible base material, subsequent application of a trigger, and
a resultant 3-dimensional transformed structure of the combined
flexible base material/active material according to an embodiment
of the present invention.
[0021] FIGS. 2A-2B illustrate a method of 3D printing an active
material onto a flexible base material according to an embodiment
of the present invention.
[0022] FIGS. 3A-C illustrate a method of laminating an active
material onto a flexible base material according to an embodiment
of the present invention.
[0023] FIGS. 4A-4C illustrate different types of activation
energies according to embodiments of the present invention.
[0024] FIGS. 5A-5D illustrate a self-transforming material
comprising a flexible base material and an active material disposed
thereon, wherein activation of a trigger results in a ventilating
material according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0025] The following definitions are useful for interpreting terms
applied to features of the embodiments disclosed herein, and are
meant only to define elements within the disclosure.
[0026] As used herein, the term "manufactured shape" or
"transformed shape" refers to a predetermined geometrical shape.
For example, according to the present invention, a manufactured or
transformed shape is different than a shape that would occur in the
flexible base material absent application of the active material,
upon application of the active material in an uncontrolled manner,
or absent exposure of the combined structure (i.e., the flexible
base material plus the active material) to a trigger that activates
the active material. In other words, a shape that is not a
predetermined shape is not a manufactured or transformed shape. It
should be understood that the term "predetermined" does not mean
that every parameter, such as volume, angle, stiffness, etc., is
known in advance, but rather that a shape is considered to be a
manufactured shape if it is generally predicted at the time of
producing the object. Depending upon the type of transformation,
the actual transformed shape may differ from the predetermined
shape by about .+-.5%, .+-.10%, .+-.30%, or .+-.50%.
[0027] As used herein, the term "self-transforming material" or
"transformable material" refers to a material that is present in a
first shape, and which, upon exposure of the material to one or
more triggers, changes shape. The shape into which the material
changes is a predetermined manufactured or transformed shape. The
self-transforming material or transformable material may be one
which changes shape reversibly or irreversibly (permanently), and a
single time or repeatedly. For example, the shape of the material
may change to the transformed shape upon exposure to a trigger, and
may then change back to the original shape upon removal of the
trigger, reversal of the trigger or exposure to a suitable
different trigger (i.e., heating to transform and then cooling to
reverse, temperature change to transform and light change to
reverse, etc.). In addition, the shape of the material may change
to the transformed shape upon exposure to a trigger, and may then
change to another second transformed shape upon exposure to a
second different trigger, and may then change back to the original
shape upon removal of the second trigger, reversal of the trigger
or exposure to a suitable different trigger.
[0028] As used herein, the term "combined structure" includes the
stretchable base material with the one or more active materials
disposed on or within the stretchable base material. The combined
structure is a self-transforming material/transformable
material.
[0029] As used within this disclosure, a "flexible base material",
which may also be referred to as a "flexible substrate material",
refers to any material that does not react to the trigger or that
reacts to the trigger in a different way than the active material
reacts. The flexible base material must be a material onto or into
which one or more active materials may be disposed, such as by 3D
printing, lamination, adhesion, or other additive manufacturing
methods. The "flexibility" of the flexible base material may either
be global or localized. In particular, a global flexibility would
generally be provided by a material that has an overall
flexibility, typically due to the nature of the material. On the
other hand, a localized flexibility would generally be provided by
a material that has an overall stiffness, typically due to the
nature of the material, but which has one or more hinges or
bendable/flexible portions which allow the material to flex along
the one or more hinges. Such hinges are typically provided along
one or more lines within the material, which are fabricated so as
to allow the material to bend or flex along the one or more lines.
The flexible base material may also be stretchable, but it is not
necessary for the flexible base material to be stretchable. Such
flexible base materials do not include composite materials.
"Composite materials", as used herein, refer to materials
impregnated with a resin, such as, for example, carbon fiber, glass
fiber, Kevlar, fiberglass, and basalt fiber, and crystal
polymers.
[0030] As used within this disclosure, a "textile" refers to a type
of stretchable base material, and includes woven, knitted, braided,
crocheted, felted, and knotted materials formed from natural and/or
artificial fibers.
[0031] As used within this disclosure, an "active material" refers
to a material that is activated by exposure to one or more
triggers. In particular, activation of the active material results
in a change in one or more properties of the active material. More
particularly, one or more properties of the active material change
upon exposure to a trigger such that the shape of the active
material changes in some way (e.g., by swelling, shrinking,
expanding, bending, folding, twisting, etc.). The active material
is a material that may be disposed on or within the flexible base
material.
[0032] The present invention generally provides a flexible base
material with one or more active materials disposed on one or more
surfaces or incorporated within the flexible base material to form
a combined structure. The combined structure is a transformable
material that automatically transforms shape in response to
exposure to one or more triggers. The present invention further
generally provides a method of forming such transformable materials
by printing, laminating, adhering, or otherwise disposing one or
more active materials on or within one or more surfaces of a
flexible base material to thereby form a combined structure. The
combined structure has a natural shape absent exposure to the one
or more specific triggers. The one or more active materials are
selected to respond to the one or more specific triggers such that,
upon exposure to the one or more specific triggers, combined
structure transforms in shape. The present invention further
generally provides complex structures formed using the
transformable materials.
[0033] Reference will now be made in detail to embodiments of the
present invention, examples of which are illustrated in the
accompanying drawings. Wherever possible, the same reference
numbers are used in the drawings and the description to refer to
the same or like parts.
[0034] According to one aspect, the present invention provides a
flexible base material 1 with one or more active materials 2
disposed thereon or therein to form a combined structure 3, which
is a transformable material.
[0035] The flexible base material 1 generally has a natural state
that is typically a flat 2-dimensional shape when resting on a
surface. The flexible base materials 1 may vary in flexibility,
with some materials providing more structure to their shape than
others. For example, some flexible base materials will generally
take on the shape of a surface they are placed upon (e.g., will be
flat when placed on a flat table, and will form a concave shape
when placed along the curvature of a bowl or other concave
structure). Other materials will generally maintain some of their
internal shape to some extent, while partially taking on a shape
they are placed upon (e.g., a thick, stiff wool which will be flat
when placed on a flat table, and may curve somewhat along the
curvature of a concave structure, but may also maintain some if
it's internal flat structure).
[0036] The material usable as the flexible base material 1 is not
particularly limited provided that it is a material that is
different than the particular active materials 2 that are used. In
particular, the flexible base material 1 is a material that, when
exposed to one or more active material triggers 4, is not itself
activated (i.e., does not change shape or properties), is minimally
or undetectably activated, or is activated in a manner different
than the manner in which the active materials 2 are activated. The
flexible base material 1 is one that has enough flexibility such
that, upon exposure of the combined structure 3 to one or more
active material triggers 4, it allows the active material 2 to
change its shape so as to provide the transformed shape 5. Some
examples of the flexible base material 1 include, but are not
limited to textiles, elastomeric materials, plastics, rubber,
leather, animal skin materials, vegan alternatives to animal skin
materials, and sheet foam. Such materials may be stretchable or
non-stretchable and, if stretchable, may be elastically/reversibly
stretchable.
[0037] The flexible base material 1 is typically any conventional
flexible (either globally or locally flexible) material that is
used in industries such as the clothing, footwear, interior
design/furniture, building, aviation, and automotive industries.
These materials are generally in the form of a 2-dimensional sheet
of the material (e.g., a piece of fabric), although it is also
possible to use what may be considered a 3-dimensional sheet of
material, which is a material having an added dimension of
thickness (particularly in the mm to cm scale thickness). Some
examples of suitable textiles include, but are not limited to,
cotton, polyester-polyurethane copolymers (e.g., Lycra.RTM.,
elastane, and spandex), neoprene, jersey, vinyl, velvet, brocade,
silk, polyesters, wool, linen, mesh, and other common stretchable
and non-stretchable materials used in forming clothing, accessories
and footwear. In addition, materials such as leather and suede, as
well as their vegan alternatives, can be used as the flexible base
material 1. The flexible base material 1 is beneficially a material
that does not require disposing the or more active materials 2
thereon or therein in any particular orientation relative to a
grain pattern, weave pattern, or knit pattern of the fibers of the
flexible base material 1 in order to provide the transformed
shape.
[0038] The active material 2 is a material that is deposited on the
flexible base material 1 in a predetermined and specific shape. The
shape is specifically designed and deposited on the flexible base
material 1 so as to provide a combined structure 3 that will take
on a transformed shape 5 when the combined structure 3 is exposed
to one or more active material trigger 4. It is noted that since it
is the active material 2 that is activated by the active material
trigger 4, the entire combined structure 3 need not be exposed to
the active material trigger 4. Rather, it is only necessary for the
active material 2 to be exposed to the active material trigger 4
either directly or indirectly. Further, as discussed further
herein, only a portion of the active material 2 can be exposed to
the active material trigger 4 to achieve activation of only some of
the active material 2, if desired.
[0039] The active material 2 can be deposited on the flexible base
material 1 using any method that allows for precise deposition of
the active material 2 in a desired pattern onto the flexible base
material 1.
[0040] Some examples of active materials 2 usable in forming the
combined structure 3 according to the present invention include,
but are not limited to, materials activated by exposure to
temperature change, exposure to light change, exposure to solvents,
exposure to various other forms of energy (e.g., electrical energy,
such as within the infrared, visible, ultraviolet, or other portion
of the electromagnetic spectrum). More particularly, the active
materials 2 can include, but are not limited to materials which are
triggered by exposure to polar solvents, such as water, alcohols,
and combinations thereof, hydrogels which are triggered by moisture
change, nylon and other plastics which are triggered by temperature
change, polystyrene and other plastics which are triggered by
light-based change. In addition, a variety of polymers are suitable
for use as the active materials 2. For example, polyethylene (PE),
(including high density polyethylene (HDPE), low density
polyethylene (LDPE)), polyethylene terephthalate (PET),
polyvinylidene fluoride (PVDF), and any variety of thermoplastic
polymers.
[0041] According to some embodiments, the active material 2 is in
the form of a heat activated material that is painted or dyed a
dark material (as opposed to the surrounding/other materials),
particularly dyed black. It is known that dark colors, particularly
black, absorb light and heat faster and more than other colors.
Thus, by providing one or more portions of the flexible base
material 1 with one or more heat activated portions that are black
in color in contrast to surrounding colors, a subsequent
application of heat by, for example, direct thermal radiation, IR
light, UV light, etc. will cause the black color to heat up the
underlying material specifically in those portions on which the
black color is provided. This dying or painting technique could
beneficially be used, for example, to provide activation along a
flexible base material 1, wherein activation is caused to a greater
extent in some locations (the dyed/painted locations) than in the
other locations.
[0042] Similar targeting of portions of the flexible base material
1 to transform to a greater extent than other portions can also be
provided by disposing different types of active materials 2 having
varying degrees of reactivity to a trigger 4, or disposing one type
of active material 2 in varying amounts on the flexible base
material (wherein a thicker deposition layer of active material 2
will generally result in a greater force of reaction, but the
thicker deposition layer of active material 2 will have more
stiffness. As such, this thicker deposition will generally result
in a faster transformation--due to the greater force--that is less
pronounced--due to the greater degree of stiffness--than a thinner
deposition). In a similar manner, the transformation can be
tailored so that some portions of the flexible base material 1 will
transform faster than other portions. This can be based on the same
concepts above, in which different active materials 2 of different
reactivity and/or different amounts of active materials 2 are
disposed in various portions.
[0043] According to various embodiments, the active material 2 is
selected to respond to a specific trigger 4 based on the end
application. For example, the transformable material may be used to
form a product, such as clothing or footwear, that will transform
as a result of exposure of the clothing or footwear to temperature
change (e.g., upon increase of body temperature or external
temperature), pressure change (e.g., upon swelling of a body part
or foot), moisture change (e.g., upon sweating), or even
light-based change (e.g., upon a change in daylight or exposure to
ambient lighting indoors).
[0044] The resultant 3-dimensional shape transformation in any
situation can be the result of various properties of both the
flexible base material 1 and the active material 2. As such, in
designing a combined structure 3, one may take into consideration
any one or more of the various properties of each of the materials.
Some possible properties that can be taken into consideration in
designing the combined structure 3 include, but are not limited to,
the type of flexible base material 1, the thickness of the flexible
base material 1, the flexibility of the flexible base material 1,
the directionality of the flexible base material, the type of
active material 2, the pattern of active material 2, the amount of
active material 2, and the difference in properties between the
flexible base material 1 and the active material 2. In addition a
plurality of active materials 2 of different type may be disposed
on the flexible base material 1 such that the properties of the
plurality of active materials, in combination, provide further
tailoring of the resultant 3-dimensional shape transformation.
[0045] According to some embodiments, one may choose to select and
maintain all but one property constant when selecting the flexible
base material 1 and active material 2, while varying the one
non-constant property in order to achieve a particular
transformation. Alternatively, multiple properties may be modified
and selected, as needed, to achieve a particular
transformation.
[0046] For example, the composition and characteristics of the
selected flexible base material 1 plays an important role in the
behavior of the combined structure 3 (e.g., breathability,
flexibility, waterproofing, etc.), the adhesion of the one or more
active materials 2, and the ultimate physical transformation of the
combined structure 3. Thus, any one or more of the particular
characteristics of various materials usable as the flexible base
material 1 can be taken into consideration, as desired, to achieve
a particular predetermined transformed shape 5.
[0047] Each material usable as a flexible base material may have
unique characteristics of directionality and flexibility, which are
capable of promoting or constraining transformation of the combined
structure 3 into the transformed shape 5. For example, one simple
implementation is illustrated in FIGS. 1A-1C, which comprises a
flexible, non-stretch flexible base material 1 with an active
material 2 (activated by heat so as to shrink) disposed on one side
of the flexible base material 1. As the combined structure 3 is
exposed to heat FIG. 1B, the active material 2 shrinks. This causes
the flexible base material 1 to curl together with the active
material 2 on the inside of the curve and the flexible base
material 1 on the outside, as illustrated in FIG. 1C.
[0048] With respect to directionality of the flexible base material
1, the warp versus weft of the flexible base material 1 may have a
directional preference, greater resistance strength, or greater
flexibility in one axis than the other.
[0049] The active material 2 generally includes one or more
materials that are printed, laminated, adhered or otherwise applied
or disposed in a particular pattern onto/within the flexible base
material 1. The particular pattern is designed so as to cause the
flexible base material 1 to geometrically transform (e.g., by
curling, folding, stretching, shrinking, creasing, curved creasing,
and the like) into a desired precise and predetermined transformed
shape 5 upon exposure of the active material 2 to one or more
active material triggers 4. These active materials 2 are generally
disposed on the flexible base material so as to remain thereon and
so that the combined structure 3 will act like a single system and
will transform into the desired precise and predetermined
transformed shape 5.
[0050] Design of the active material pattern 2 can be varied in
light of the characteristics of the flexible base material 1. For
example, depending upon the flexibility and/or directionality of
the flexible base material 1, the thickness (i.e., height), width,
and/or pattern of the active material 2 can be tailored so as to
achieve a precise transformed structure. Alternatively, the
thickness (i.e., height), width, and/or pattern of the active
material 2 can be determined first, and then the flexible base
material 1 can be subsequently chosen so as to have the necessary
characteristics (such as flexibility and/or directionality) that
will achieve a precise transformed structure.
[0051] In general, varying the amount of active material 2 (e.g.,
layer width, a layer height, and/or pattern density), while
maintaining all other properties without modification, will
generally result in the active material 1 having more or less
strength or transformation capability. For example, more active
material 2 typically results in greater active material strength
(i.e., activation and transformation strength or force), but
generally results in a slower transformation (i.e., time it takes,
upon activation, to reach the final transformed shape). On the
other hand, less active material 2 usually results in less
strength, but generally results in a faster transformation.
[0052] Various active materials 2 can be utilized to promote shape
transformation or respond to various external stimuli, i.e., active
material triggers 4. An important factor when selecting the active
material 2 is the amount of expansion or contraction of the active
material based on certain triggers 4, and sometimes the intensity
of the trigger (i.e., the intensity of the external stimulus). For
example, a hydrogel-based material will swell when subject to
water. When such a hydrogel-based material is used as the active
material 1 s, and is disposed onto a flexible base material 1, this
swelling effect will cause the flexible base material 1 to curl
with the hydrogel active material 2 on the outside of the curl and
the flexible base material 1 on the inside (basically the opposite
transformation as the one depicted in FIG. 1C).
[0053] According to preferred embodiments, activation of the active
material 2 results in expansion or contraction. Preferably, the
active material 2 is designed to have a differential expansion or
contraction (e.g., different coefficients of thermal expansion,
different absorption characteristics of electromagnetic energy,
etc.) greater or less than that of the flexible base material 1,
preferably significantly greater or less than that of the flexible
base material. While a small difference in the expansion or
contraction properties of the active material 2 vs. the flexible
base material 1 can still provide some transformation in shape,
such a transformation may be small or even unnoticeable. Thus, it
is preferred that the difference in these properties is such that
the active material 2 is at least about 20%, 30%, 40%, 50%, 60%
70%, 80%, 90%, and up to 100% (wherein the flexible base material
is completely non-reactive) more reactive than the base material 1.
Similarly, if the two materials 1, 2 were selected to have roughly
equal expansion or contraction, then the combined material 3 would
generally not undergo a 3-dimensional transformation according to
the present invention, rather, the combined material may, for
example, shrink or swell as a whole along a plane. In particular,
according to embodiments of the present invention, the exposure of
the combined structure 3 causes the active material 2 to respond to
a greater extent (e.g., by swelling to a large extent) than the
flexible base material 1 (e.g., which may not swell at or, may
swell to a relatively small degree, or may even expand). As a
result of this difference in response between the flexible base
material 1 and the active material 2, the combined structure 3
transforms from its state absent the trigger 4 into a second shape
(e.g., by curling). Generally, a greater relative degree of
swelling (or particular reaction) between the two materials 1, 2
leads to a greater degree of deformation in the combined structure
3. In addition, the relative stiffness of the flexible base
material 1 and the active material 2 affects the extent of
distortion in the combined structure 3. For example, a stiffer
active material 2 and a softer flexible base material 1 will permit
greater deformation. On the other hand, a very soft active material
2 can be inefficient in creating deformation in a combined
structure 3 having a flexible base material with relatively greater
stiffness. In other words, if the active material 2 is very soft,
it may not exert enough force to resist the flexible base material
1, so the combined structure 3 shape will not change. In addition,
a thicker active material 2 will cause greater deformation that a
thinner active material 2. As such, the selection of active
material 2 should be different than the flexible base material
1.
[0054] The active material 2 can be disposed onto/within the
flexible base material 1 in any manner that forms a strong bond
between the active material 2 and flexible base material 1 such
that the active material 2 and flexible base material 1 will
together transform, as a combined structure 3, into the
predetermined shape.
[0055] One preferred implementation of disposing active material 2
onto one or more surfaces of the flexible base material 1 is by
means of printing, particularly 3D printing. 3D printing has
conventionally been used to create static objects and other stable
structures, such as prototypes, products, and molds. Three
dimensional printers can convert a 3D image, which is typically
created with computer-aided design (CAD) software, into a 3D object
through the layer-wise addition of material. In the present
invention, 3D printing can be used to create, design, and print a
custom height, width and pattern of active material 2 on top of the
flexible base material 1. According to preferred embodiments, 3D
geometric shapes are achieved using computer software loadable from
a non-transient computer-readable medium, which can be used to
calculate the pattern and design specifications in which the active
materials 2 are printed on the flexible base material 1 for
subsequent transformation to the precise and predetermined 3D
geometric shape. For example, the pattern of the printed active
material 2 can be designed by reference to the predetermined 3D
geometric shape (transformed shape), and computer software loadable
from a non-transient computer-readable medium can be used to
calculate the pattern in which the active material 2 is printed for
subsequent transformation to the transformed shape.
[0056] Any 3D printing technology can suitably be used in the
present invention to dispose the desired active materials 2 on the
flexible base material 1. One example of such a 3D printing
technology includes multi-material three-dimensional (3D) printing
technologies, which allow for deposition of material patterns with
heterogeneous composition. For example, 3D printed structures can
be composed of two or more active materials having particular
physical and chemical properties. The Objet.RTM. line of 3D
printers (Stratasys Ltd., Israel) can be used for the 3D printing
of multi-material objects. Such printers are described in U.S. Pat.
Nos. 6,569,373; 7,225,045; 7,300,619; and 7,500,846; and U.S.
Patent Application Publication Nos. 2013/0073068 and 2013/0040091,
each of the teachings of which being incorporated herein by
reference in their entireties. The Stratasys.RTM. Connex.TM.
multi-material printers provide multi-material Polyjet.TM. printing
of materials having a variety of properties, including rigid and
soft plastics and transparent materials, and provide
high-resolution control over material deposition.
[0057] One of skill in the art will understand that it may be
necessary to cure (e.g., polymerize) the 3D printed active
material. For example, it will typically be necessary to cure the
active material 2 prior to exposure to the active material trigger
4.
[0058] A simplified depiction of 3D printing is shown in FIGS.
2A-2B, in which a printer filament 5 and printer nozzles 6 are
positioned so as to deposit the active material 2 onto flexible
base material 1. A side view of the printed active material 2 is
depicted in FIG. 2B, in which the active material 2 is provided
with a particular height "h" and width "w" which is designed and
provided so as to contribute to achieving the desired transformed
shape.
[0059] According to further embodiments, the active material 2 is
deposited onto the flexible base material 1 through lamination or
adhesion. For example, as depicted in FIGS. 3A-3C, one or more
active materials 2 are formed into the desired patterns (which may
simply be a sheet of material to overlay the entire or a portion of
the base material 1) to be deposited onto the stretchable base
material 1 (e.g., through laser-cutting, CNC routing, or any other
method of forming the desired pattern for subsequent lamination or
adhesion). Typically the active material 2 is then laminated or
adhered to one surface of the flexible base material 1 as depicted
in FIG. 3A. However, in some embodiments, an upper and a lower
surface of the flexible base material 1 may have active materials 2
laminated or adhered thereto, resulting in a flexible base material
1 sandwiched between the top and bottom active materials 2. These
two active materials 2 may be identical in structure as shown in
FIGS. 3B-3C, or there may be a structure on an upper surface than
on the lower surface. In addition, the particular materials used as
the active materials 2 on the upper and lower surface may be the
same or they may be different.
[0060] This process of laminating or adhering the physical
constraint 2 to the pre-stressed stretchable base material 1
creates a similar transformable material as that formed with 3D
printing. While this alternate method allows for quick production
of the active material 2 on the flexible base material 1, it can
limit the nature of the 3-dimensional structure that can be created
since the laser cut or CNC routed laminated sheets cannot be
provided with as intricate detail as 3D printed patterns. In
particular, 3D printing is particularly beneficial because it
allows for a much more complex structures, as well as variable
height/width of the deposited active materials and, thus, can
provide a user with more control over the final transformed shape.
Further, with adhesion, the glue or other material used to adhere
the active material 2 to the flexible base material 1 must also be
carefully selected because it essentially creates another layer of
material having properties that can impact the transformable
material. Preferably, thus, glue or other material is selected so
that its properties do not interfere with or impact the properties
of the flexible base material 1 and the active material 2 (e.g., it
can be a very pliable, stretchable, flexible material that will
take on any form that is imposed upon it by the flexible base
material 1 and the active material 2).
[0061] As in the implementations using 3D printing, when using
lamination or adhesion, the pattern, width/thickness and material
properties of the added laminated or adhered active material 2 will
contribute to the resultant manufactured or transformed shape.
Also, using either method, multiple layers of materials and
different regions of relatively flexible and stiff materials can be
deposited to create a complex combined structure 3 based on the
desired transformed shape. Further, as with 3D printing, one of
skill in the art will understand that it may be necessary to cure
(e.g., polymerize) the laminated or adhered active material and any
glue or adhesive utilized. For example, any glue or adhesive must
be fully cured, and it is generally necessary to cure the active
material 2 material prior to exposure of the combined structure 3
to the trigger 4, and prior to transformation of the
shape--otherwise, the active material 2 may separate from the
flexible base material 1 which may result in the transformed or
manufactured shape not being formed properly.
[0062] According to further embodiments, the active material 2 may
be disposed on the flexible base material 1 by knitting, weaving,
stitching, injecting or other processes of material addition. As in
the implementations using 3D printing and lamination, the pattern,
width/thickness and material properties of the active material 2
will contribute to, in relation to the direction and
flexibility/stiffness of the flexible base material 1, will dictate
the resultant shape transformation.
[0063] According to the present invention, the active material 2
should be sufficiently bonded to the flexible base material 1 to
provide a successful transformed shape (i.e., one that achieves the
final desired transformed shape and holds the transformed shape as
needed). This bonding may be produced by 3D printing materials,
such as plastics, with the correct melting temperature and material
properties to sufficiently bond with the flexible base material 1.
Similar bonding may also be produced with adhesives for a
lamination process or by mechanical means of stitching, riveting or
other physical connection means. While not being bound by theory,
it is believed that the better the active material 1 is bound to
the flexible base material 1, the more the flexible base material 1
and the active material 2 will act as a single system and will
transform in the correct transformed shape 5.
[0064] In addition, according to some embodiments, an active
material 2 may be bonded to the flexible base material 1 only along
portions of the active material 2. As a simple example, the
flexible base material 1 may be a simple rectangular, flat piece of
a fabric. The active material 2 may also be a simple rectangular,
flat piece of material. If only two opposing edges of the
rectangular active material 2 are bonded to the corresponding edges
of the rectangular flexible base material 1, then a different
resultant transformed shape would result than in two strips of
active material 2 were bonded to the corresponding edges of the
rectangular flexible base material 1. In particular, using the
entire sheet of active material which is selectively bonded, if the
active material is activated, the two bonded strips will change the
shape of the flexible base material, but the loose (un-bonded)
portion of the active material will also play a role in the
transformation.
[0065] As discussed, the present invention provides active
self-transforming materials, wherein the transformation is the
result of one or more active material triggers 4. As such, another
aspect of the present invention relates to the specific type of
trigger 4 that is applied to the combined structure 3. In general,
the active material trigger 4 is an external stimulus that is
configured to cause a predicted transformation of the combined
structure 3 from its natural shape to the transformed shape to
exposure of the active material 2 to the external stimulus. If
there are no specific limitations as to the environment in which
the combined structure 3 is being used, then any type of active
material 3 having any related trigger 4 can be used. However, where
the combined structure 3 is being designed so as to react to a
particular trigger 4, the active material 2 must be selected
accordingly.
[0066] For example, hydrogels can be used for moisture change,
nylon or other plastics for temperature change, polystyrene or
other plastics for light-based change, etc. Appropriate selection
of the active material 2 can, thus, be made based on the type of
active material trigger 4. According to one preferred
implementation, a plastic-based material, such as Nylon, is
disposed as the active material 2 onto a textile flexible base
material 1, which causes the resultant combined structure to curl
and un-curl in response to heat application (e.g., an increase in
body heat). This action can be used to design an article of
clothing that forms vents when the wearer's body temperature
increases or when the external temperature increases. One depiction
of this in in FIGS. 5A-5D. As shown, a flexible base material 1 can
be formed with one or more flaps 8 disposed therein. The active
material 2 may be disposed on the surface of the flaps 8 (FIG. 5B)
to form vents 9. The active material 2 is selected and disposed in
such a way that when exposed to the active material trigger 4
(here, heat), the vents 9 lift up and away from (e.g., by curling)
the remainder of the flexible base material 1 forming the
garment.
[0067] Further, a single material or multiple materials can be used
simultaneously as the active material 2 to create different
transformations based on different triggers 4. For example, both a
hydrogel and Nylon can be disposed as active materials on a
flexible base material 1 to produce a custom combined structure 3
that can transform one direction when subject to moisture, can then
transform in another direction when subject to heat, and can
finally transform in a third direction when subject to hot water.
Such multiple active materials 2 can be disposed in any desired
manner on the flexible base material 1. For example, any number of
different active materials maybe provided in multiple layers (e.g.,
with a first material on a bottom layer and a second material on a
top layer) and/or may be provided in separate layers (e.g., with a
first material forming a first pattern and a second material
forming a second pattern).
[0068] In general, the type, amount, and location of the active
material trigger 4 (i.e., external stimulus) applied to the
combined structure 3 will create different transformation
characteristics based on the pattern and amount of active material
2. For example if a minimal amount of heat triggered active
material 2 is disposed on only a portion of a flexible base
material 1, and then heat is applied to the entire combined
structure 3, the resultant transformation will be based on the
selective pattern of active material 2. The flexible base material
1 without the active material 2 preferably does not respond to the
heat--rather, only the heat triggered active material 2 will shrink
and cause local transformation. Conversely, if an entire surface of
the flexible base material 1 has a pattern of the heat triggered
active material 2 disposed thereon, a very different transformation
may occur thank in the previous example if the entire combined
structure 3 is subject to heat. For example, a global curling shape
would likely emerge rather than local transformation in the
previous example. In addition, the heat may be applied in a precise
and local pattern on the combined structure 3 so as to provide a
local transformation rather than a global transformation--in other
words, only a portion of the active material 2 may be exposed to
the heat and, thus, activated. This demonstrates that the location
of the applied active material trigger 4 can have a direct impact
on the type of transformation.
[0069] Similarly, varying the amount of activation (i.e., intensity
of the trigger/external stimulus) can cause different
transformation characteristics. For example, if more heat (or any
other trigger) is applied in a short amount of time (as opposed to
less heat), this may speed up the transformation, depending on the
characteristics of the active material 2. The length of time may
also impact the shape transformation, where a longer application of
heat (or any other trigger) may produce a different shape by
allowing the combined structure 3 to transform more than if the
heat was applied only for a short amount of time.
[0070] Finally, different types of triggers, in relation to the
active material 2, can cause different transformation
characteristics. For example, water-activated materials may tend to
transform slower and less repeatable than heat-active materials.
Light-active materials may tend to react quicker, but could be
single-direction (irreversible) whereas a heat-active material may
be completely reversible and repeatable.
[0071] As such, one or more of the location and type of active
material, the type of trigger, the level of external stimuli (i.e.,
intensity of the trigger), and the duration of exposure to the
trigger may be designed specifically with the particular
application and environment of use in mind.
[0072] The 3-dimensional transformed shape 5, thus, is a result of
the careful design of (1) the material property and directionality
of flexibility/stiffness of the flexible base material 1, (2) the
properties, amount and 2 or 3-dimensional pattern of the active
material 2, and (3) the amount, pattern, and duration of active
material trigger 4. This relationship can be simplified and easily
controlled if, for example, a single flexible base material 1,
active material 2 and activation energy are used. This leaves only
the pattern and quantity of the deposited active material 2, and
thus, the pattern of the active material 2 becomes the "program"
for creating precise self-transforming materials. Of course, other
features could be maintained constant with others are varied (i.e.,
the varied features becoming the "program"), depending upon the
particular objectives and environment in which the material will be
used.
[0073] If desired, the combined structure 3 can include one or more
additives, such as one or more photoinitiator, surface active
agent, stabilizer, and inhibitor. Such additives can be included in
the flexible base material 1 and/or the active material 2.
[0074] The present invention beneficially allows for precise
control over 3-dimensional self-transformations for combined
structures 3 including active materials 2. Complex, precise and
pre-determined transformed shapes can be achieved such as textile
detailing, patterning and fashion/apparel texturing (ripple
patterns, tufting, pleating, etc.) or larger repeatable
transformations for comfort, custom fit or openings (sinusoidal
waves, various degrees of positive and negative curvature,
cut/vents, etc.). The present invention offers significant
advantages over traditional methods of making complex geometry,
curvature or detailing in flat textiles.
[0075] In particular, the present invention provides a method
capable of producing predictable and unique geometric structures
from traditionally passive, flat materials to thereby open up new
opportunities for a variety of products and industrial
manufacturing processes. By reducing the manual labor, time and
skill required to form materials into complex shapes, the present
techniques provide significant efficiencies and manufacturing
opportunities. Similarly, by introducing a new method for creating
highly active self-transforming materials, entirely new products
can be imagined that would not have been previously possible. The
present invention further offers the ability to develop entirely
new forms and complex textile structures that can transform
repeatedly based on the environment or supplied energy/trigger.
[0076] Further, rather than utilizing conventional techniques,
which require stretching and forcing materials around a physical
mold, the present invention allows a single sheet of material to
self-transform into any arbitrary 2D or 3D structure based on
activation energy/trigger. As such, the use of molds can be
entirely eliminated, thereby reducing the cost and limitations for
a single product type. The present techniques also allow for
customizable products to be easily produced and for entirely new
types of products to be developed that would previously not have
been possible with a subtractive-milled mold.
[0077] In addition, new products are also now possible that can
self-transform and adapt to the user or the type of use and
fluctuating environments. Currently, nearly all products are
designed to be static with a single function and fit. For example,
shoes and clothing are designed for a single type of use, and do
not adapt if the user changes from one climate to another, if they
start to run versus walk, if they grow or gain/loose weight, etc.
Using the present active self-transforming materials, clothing,
shoes, and other items can now be designed to change, for example,
to open or close to allow active venting/cooling/heating, transform
shape for water proofing or moisture retention, and independently
morph for added comfort or structure based on a user's activity.
For example, someone might want a loose-fit shirt for everyday use,
and may want a tighter-fit shirt when playing sports--using the
present transforming materials, one can have a single shirt that
provides both desired fits. This can be desirable, for example,
when a wearer decides to participate in a sport at the last minute
after work, and would otherwise not have the proper clothing to do
so. Similarly, a garment may open as the external temperature
increases to actively cool the person, or may close when it is a
cooler environment. The garment may also open in specific places if
the person starts playing a sport or increasing their body
temperature. In addition, the transformable materials can provide
more a customized fit for apparel and footwear, and can provide
complex curvature (i.e. for the body or foot) without darting,
patterning or patching material. Thus, entirely new product
concepts can be realized with present active self-transforming
materials, which are capable of morphing their shape and/or
performance based on the user's body, comfort, new design or
aesthetic preferences, fluctuating environments and changing
activities.
[0078] The present active self-transforming materials can also be
designed to create dynamic performance increase--including
aerodynamics, moisture control, temperature control or other
properties which provide highly dynamic complex
shapes/textures/patterns that may create a competitive advantage.
For example, by controlling the shape and resultant
flexibility/stiffness and actuation of the transforming material, a
dynamic combined structure surface can transform on an athlete to
increase or decrease aerodynamic resistance or breathability for
higher performance. Similarly, the present transformable materials
can dynamically apply pressure in various points of the body to
increase and/or control blood-flow, and form active compression
garments for athletic and/or medical benefits. Such transformable
materials can also be used to form dynamic support for enhanced
strength, walking or other physical maneuvers (i.e., a tunable
textile exoskeleton). Likewise, the present transformable materials
can provide dynamic apparel or footwear for different environments,
dynamic body conditions or varied user performance (e.g., running
vs. walking etc.). Using the present transformable materials,
environmentally adaptive clothing and footwear can be provided
wherein, for example, footwear can be designed to automatically
pull together and become more water resistant when exposed to
moisture, or to expand and allow more airflow if the foot becomes
too hot. The present transformable materials could also be used in
providing structures like shoe soles, tires, and other structures
provided with a grip-like surface to change their grip in response
to moisture (e.g., a shoe sole or tire that can change its
tread/grip as it gets wet).
[0079] The world of interior design can, likewise, benefit from the
present transformable materials. In particular, the materials could
be used in forming self-transforming furniture or other interior
products that can transform in shape on demand, simply by
application of an appropriate trigger. Further, complex and
3-dimensional interior partitions and other wall treatments (e.g.,
blinds and other window treatments) can be fabricated using the
present transformable materials in such a way that they
self-transform based on fluctuating environments. For example,
blinds or other window treatments can be fabricated of a flexible
base material with an active material that is activated by light
fluctuations. As such, the blinds or window treatments may be in
one position when the lighting conditions are dark, and may
automatically change (e.g., the blinds may close) when exposed to
light (e.g., either the external light to provide shielding from
the sun, or internal light to provide a person in their home at
night with the lights on with privacy.
[0080] In addition, in any situation where a sensor utilized, in
which the sensor detects a change in an environment (e.g.,
temperature change, change in moisture level, change in electrical
energy, exposure to one or more solvents, etc.), the present
material can be used as the sensor or in forming the sensor. In
particular, upon exposure to the desired change that is to be
detected, the present material can change shape in a manner that
will alert a person to that change. Likewise, in any situation
where a switch is utilized, wherein the switch is activated by
changes in the environment by opening or closing (e.g., temperature
change, change in moisture level, change in electrical energy,
exposure to one or more solvents, etc.), the present material can
be used as the sensor. In particular, the material can be provided
so as to change shape and function as a switch upon exposure to the
applicable change in the environment. Further, in any situation
where an actuator utilized, in which the actuator can detect a
change in an environment (e.g., temperature change, change in
moisture level, change in electrical energy, exposure to one or
more solvents, etc.), the present material can be used as the
actuator or in forming the actuator. In particular the present
material can be formed into a structure such that exposure to one
or more trigger causes the actuator to change shape so as to push
or pull something to cause actuation.
[0081] It will be apparent to those skilled in the art that various
modifications and variations can be made to the structure of the
present invention without departing from the scope or spirit of the
invention. In view of the foregoing, it is intended that the
present invention cover modifications and variations of this
invention provided they fall within the scope of the following
claims and their equivalents.
* * * * *