EP4669513A1 - Personalized adaptive objects produced through additive manufacturing - Google Patents

Personalized adaptive objects produced through additive manufacturing

Info

Publication number
EP4669513A1
EP4669513A1 EP24701991.2A EP24701991A EP4669513A1 EP 4669513 A1 EP4669513 A1 EP 4669513A1 EP 24701991 A EP24701991 A EP 24701991A EP 4669513 A1 EP4669513 A1 EP 4669513A1
Authority
EP
European Patent Office
Prior art keywords
fabric
adaptive
smp
adaptive device
present disclosure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24701991.2A
Other languages
German (de)
French (fr)
Inventor
Elham KHODABAKHSHISHALAMZARI
Simon Stahl
Nadejda Krasteva
Silvia Rosselli
Sebastiana ROCCUZZO
Anthony Roberts
Gabriele Nelles
Vitor Angelo FONSECA DEICHMANN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sony Europe BV
Sony Semiconductor Solutions Corp
Original Assignee
Sony Europe BV
Sony Semiconductor Solutions Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sony Europe BV, Sony Semiconductor Solutions Corp filed Critical Sony Europe BV
Publication of EP4669513A1 publication Critical patent/EP4669513A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/04—Pigments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/70—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyurethanes
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS
    • H04R1/00—Details of transducers, loudspeakers or microphones
    • H04R1/10—Earpieces; Attachments therefor ; Earphones; Monophonic headphones
    • H04R1/1016—Earpieces of the intra-aural type
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS
    • H04R25/00—Electric hearing aids
    • H04R25/65—Housing parts, e.g. shells, tips or moulds, or their manufacture
    • H04R25/652—Ear tips; Ear moulds

Definitions

  • the field of the DISCLOSURE lies in adaptive objects and materials for implementation in textiles, ear buds, wearables and smart clothing.
  • the present disclosure relates to adaptive devices or fabrics, comprising shape memory polymer(s) and optionally thermochromic pigment(s), wherein the device or fabric is obtained by fused deposition molding and has different states it reversibly changes in between depending on heating.
  • the present invention further relates to methods of producing said adaptive devices or fabrics.
  • the present disclosure also relates to the use of said adaptive devices or fabrics, in particular, their use for customizable ear buds, semi-woven textiles, parts of smart textiles, wearables and/or gaming gloves and suits.
  • the present disclosure also relates to an ear bud or hearing aid as well as to an adaptive semi-woven 3D printed textile or clothing item.
  • ears come in all shapes and sizes so there is not a one-size-fits-all hearing aid solution to the discomfort they cause.
  • the commercially available hearing aids and ear plugs products are not nicely fitting to every one’s ear, therefore exploring a custom fit hearing aid that may be tailored more specifically for each individual needs is required.
  • the present disclosure provides an adaptive device or fabric comprising:
  • a shape memory polymer which has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, and which reversibly changes shape when heated above its glass transition temperature, and
  • thermochromic pigment(s) wherein the device or fabric is obtained by fused deposition molding, preferably 3D printing, and wherein the device or fabric has different states it reversibly changes in between in dependence on said heating.
  • the present disclosure provides a method of producing an adaptive device according to the disclosure, comprising the steps:
  • the present disclosure provides a method of producing an adaptive fabric according to the disclosure, comprising the steps:
  • the present disclosure provides an adaptive device or fabric obtained by a method of the present disclosure.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in customizable ear buds.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in customizable hearing aids.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in semi-woven textiles.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in clothing items.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in parts of smart textiles.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in wearables.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in functional underwear.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming gloves.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming suits.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming headsets.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming chairs. [0026] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming controllers.
  • the present disclosure provides an ear bud or hearing aid comprising at least one adaptive device of the present disclosure or an adaptive device obtained by a method of the present disclosure.
  • the present disclosure provides an adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive fabric of the present disclosure or an adaptive fabric obtained by a method of the present disclosure.
  • Figure 1 shows an adaptive device or fabric of the present disclosure and its possible reversible shape changes.
  • Figure 2 shows an ear bud as an adaptive device of the present disclosure.
  • Figure 2A shows the ear bud in its initial hard state with its initial color.
  • Figure 2B shows the ear bud in its programmed state. The color indicates that its temperature is above the SMP’s glass transition temperature.
  • Figure 2C shows the ear bud as applied into the ear.
  • Figure 3 shows a textile which was obtained with the method of the present disclosure.
  • Figure 4A shows a textile which was obtained with the method of the present disclosure.
  • Figure 4B is a close-up of the textile of Figure 4A.
  • Figure 5 shows a 3D printer as used in the methods of the present disclosure.
  • the present disclosure provides an adaptive device or fabric.
  • Said adaptive device or fabric comprises
  • a shape memory polymer which has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, and which reversibly changes shape when heated above its glass transition temperature; and
  • thermochromic pigment(s) (ii) optional, thermochromic pigment(s).
  • the adaptive device or fabric is obtained by fused deposition molding, preferably 3D printing.
  • FDM Fused deposition modeling
  • FFF fused filament fabrication
  • the adaptive device or fabric has different states it reversibly changes in between in dependence on said heating.
  • the shape memory polymer (SMP) (i) has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, preferably about 35°C to 45°C, more preferably about 35°C to 40°C.
  • Tg glass transition temperature
  • the SMP has a glass transition temperature in the range of the body temperature.
  • the shape memory polymer (SMP) (i) is thermoplastic polyurethane (TPU). In one embodiment, the SMP is about 100% TPU.
  • the shape memory polymer does not contain polylactic acid (PL A), polyvinyl alcohol (PVA), polybutylene succinate (PBS) or acrylonitrile butadiene styrene (ABS).
  • PL A polylactic acid
  • PVA polyvinyl alcohol
  • PBS polybutylene succinate
  • ABS acrylonitrile butadiene styrene
  • the adaptive device or fabric comprises more than one SMP, wherein each SMP has a different glass transition temperature.
  • the adaptive device or fabric comprises up to five different SMPs. In one embodiment, the adaptive device or fabric comprises two different SMPs. In one embodiment, the adaptive device or fabric comprises three different SMPs. In one embodiment, the adaptive device or fabric comprises four different SMPs. In one embodiment, the adaptive device or fabric comprises five different SMPs.
  • the heating is carried out passively, such as by body temperature. [0045] In one embodiment, the heating is carried out actively, preferably by a heating element. [0046]
  • the heating element can be rigid.
  • the heating element can be bendable or flexible.
  • the heating element can be a wire.
  • the heating element is printed together with the SMP.
  • the adaptive device or fabric has different states it reversibly changes in between in dependence on the heating.
  • the different states are:
  • the adaptive device or fabric acquires a desired shape, when cooled down, preferably below the glass transition temperature. It can be frozen into said desired shape.
  • the cooling down can be carried out passively by convection, conduction or radiation.
  • the cooling down can be carried out actively, preferably by a heating element, such as a Peltier element.
  • the adaptive device or fabric returns to its initial state when it is reheated above its glass transition temperature.
  • the adaptive device or fabric returns to its initial state, when it is reheated above its glass transition temperature, and it can then acquire a next /another desired shape.
  • the adaptive device or fabric comprises one or more thermochromic pigments (ii).
  • the thermochromic pigments are preferably selected from spirolactones, fluorans, spiropyrans, or fulgides compounds.
  • thermochromic pigment(s) are incorporated in a polymer matrix.
  • thermochromic pigment is preferably not added as such but is included in a polymer matrix.
  • the polymer matrix can be a so-called thermochromic masterbatch (TCMB).
  • the base polymer matrix such as the TCMB, can be low-density polyethylene (LDPE) or thermoplastic polyurethane (TPU).
  • LDPE low-density polyethylene
  • TPU thermoplastic polyurethane
  • the content of pigment is preferably in the range from about 20% to about 45%.
  • thermochromic pigment shows the temperature of the device or fabric at a given moment to the user and/or to a camera.
  • thermochromic effect of the adaptive device or fabric indicates visually whether the adaptive device or fabric is in the heated or cold state. The visual indication gives useful feedback to the user interface.
  • the present disclosure provides a method of producing an adaptive device according to the disclosure.
  • Said method comprises the steps:
  • thermochromic pigment(s) are included in the adaptive device
  • step (1) a mixture is extruded into a filament, wherein said mixture comprises or consists of SMP and the thermochromic pigment(s), which is/are included or incorporated in a polymer matrix,
  • it can be a mixture of about 90% to about 99% SMP(s) and about 1% to about 10% TCMB, preferably about 92% to about 98% SMP(s) and about 2% to about 8% TCMB, more preferably about 95% SMP(s) and about 5% TCMB.
  • the 3D printer which is used in step (2) comprises:
  • the feeding tube connects the filament feeding gears with the heat break and passes through the cooler.
  • the feeding tube ends where the heat break starts.
  • the heat break connects the cooler and the heating block, wherein thermally conductive paste is applied on the thread between the heat break and the cooler.
  • the heat break is the only connection between cooler and heating block.
  • the heating block connects the heat break and the single printing nozzle.
  • the thermally conductive paste is only applied between the heat break and the cooler, and it is not applied between the heat break and the heating block.
  • a suitable thermally conductive paste is a paste comprising carbon microparticles, e.g. MX-4 thermal paste (ARCTIC GmbH, Germany).
  • step (1) for each SMP a different filament is extruded.
  • the different filaments are preferably fed together into one single feeding tube.
  • the single printing nozzle has a diameter in the range from about 0.2 mm to about 1 mm.
  • Examples for the diameter of the single printing nozzle are about 0.25 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm or about 0.8 mm.
  • the heating break is made of titanium or a titanium alloy.
  • titanium Grade 5 EN 3.7165 or Ti Gr 5 / 3.7165.
  • the present disclosure provides a method of producing an adaptive fabric according to the disclosure.
  • Said method comprises the steps:
  • step (3) the printing speed and/or the extrusion factor is modified in order to deliberately introduce defects into the printed fabric. This modification results in a textile structure which is flexible, bendable and/or stretchable.
  • the printing speed can be modified, for example, between 25 and 200mm/2.
  • the extrusion factor can be modified, for example, by 0.3-0.8 or 30-80%.
  • thermochromic pigment(s) are included in the adaptive device
  • step (1) a mixture is extruded into a filament, wherein said mixture comprises or consists of SMP and the thermochromic pigment(s), which is/are included or incorporated in a polymer matrix,
  • it can be a mixture of about 90% to about 99% SMP(s) and about 1% to about 10% TCMB, preferably about 92% to about 98% SMP(s) and about 2% to about 8% TCMB, more preferably about 95% SMP(s) and about 5% TCMB.
  • the 3D printer which is used in step (2) comprises:
  • the feeding tube connects the filament feeding gears with the heat break and passes through the cooler.
  • the feeding tube ends where the heat break starts.
  • the heat break connects the cooler and the heating block, wherein thermally conductive paste is applied on the thread between the heat break and the cooler.
  • the heat break is the only connection between cooler and heating block.
  • the heating block connects the heat break and the single printing nozzle.
  • the thermally conductive paste is only applied between the heat break and the cooler, and it is not applied between the heat break and the heating block.
  • a suitable thermally conductive paste is a paste comprising carbon microparticles, e.g. MX-4 thermal paste (ARCTIC GmbH, Germany).
  • step (1) for each SMP a different filament is extruded.
  • the different filaments are preferably fed together into one single feeding tube.
  • the single printing nozzle has a diameter in the range from about 0.2 mm to about 1 mm.
  • Examples for the diameter of the single printing nozzle are about 0.25 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm or about 0.8 mm.
  • the heating break is made of titanium or a titanium alloy.
  • titanium Grade 5 EN 3.7165 or Ti Gr 5 / 3.7165.
  • the present disclosure provides an adaptive device or fabric obtained by a method of the present disclosure.
  • the present disclosure provides the use of the adaptive device or fabric the present disclosure, or the adaptive device or fabric obtained by a method of the present disclosure.
  • the adaptive device or fabric obtained by a method of the present disclosure.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in customizable ear buds.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in customizable hearing aids.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in semi-woven textiles.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in clothing items.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in parts of smart textiles. [0092] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in wearables.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for functional underwear.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming gloves.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming suits.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming headsets.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming chairs.
  • the present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming controllers.
  • the present disclosure provides an ear bud or hearing aid comprising at least one adaptive device of the present disclosure.
  • the present disclosure provides an ear bud or hearing aid comprising at least one adaptive device obtained by a method of the present disclosure.
  • the ear bud or hearing aid comprises said adaptive device with two different SMPs each having a different glass transition temperature.
  • the first SMP has a glass transition temperature close to body temperature, such as about 35 to 45°C.
  • the first SMP is located on the outside or the surface of the ear bud or hearing aid.
  • the second SMP has a glass transition temperature which is higher than the glass transition temperature of the first SMP, such as 45 to 70°C.
  • the second SMP is preferably located inside the earing bud or hearing aid.
  • the ear bud or hearing aid comprises a thermochromic pigment.
  • the thermochromic pigment preferably shows the temperature of the ear bud or hearing aid at a given moment to the user.
  • the present disclosure provides an adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive device of the present disclosure.
  • the present disclosure provides adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive device obtained by a method of the present disclosure.
  • the textile or clothing item comprises said adaptive fabric with two different SMPs each having a different glass transition temperature.
  • the textile or clothing item comprises more than one adaptive fabric.
  • the textile or clothing item comprises local areas comprising the adaptive fabric.
  • the textile or clothing item does not comprise natural fibers, such as wool or cotton, and/or polyester or polyamide.
  • the textile or clothing item comprises a thermochromic pigment.
  • the thermochromic pigment preferably shows the temperature of the ear bud or hearing aid at a given moment to the user or to a camera.
  • An adaptive device or fabric comprising
  • a shape memory polymers which has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, preferably about 35°C to 45°C, more preferably about 35°C to 40°C, and which reversibly changes shape when heated above its glass transition temperature, and
  • thermochromic pigment(s) wherein the device or fabric is obtained by fused deposition molding, preferably 3D printing, and wherein the device or fabric has different states it reversibly changes in between in dependence on said heating, preferably a soft and flexible state and a hard and less flexible state.
  • shape memory polymer is thermoplastic polyurethane (TPU) (such as 100% TPU), and wherein the shape memory polymer (SMP) preferably does not contain polylactic acid
  • PL A polyvinyl alcohol
  • PBS polybutylene succinate
  • ABS acrylonitrile butadiene styrene
  • thermochromic pigment(s) is/are selected from spirolactones, fluorans, spiropyrans, or fulgides compounds, wherein the thermographic pigment(s) is/are preferably incorporated in a polymer matrix, and/or wherein the thermochromic pigment shows the temperature of the device or fabric at a given moment to the user.
  • a single printing nozzle wherein the feeding tube connects the filament feeding gears with the heat break and passes through the cooler and wherein the heat break connects the cooler and the heating block and wherein the heating block connects the heat break and the single printing nozzle, and wherein thermally conductive paste is applied on the thread between the heat break and the cooler; and (3) Printing the adaptive fabric from the single printing nozzle, wherein during printing the printing speed and/or the extrusion factor is modified in order to deliberately introduce defects into the printed fabric, which results in a textile structure which is flexible, bendable and/or stretchable.
  • An ear bud or hearing aid comprising at least one adaptive device of any one of (1) to (7) or obtained by a method of any one of (8), (10) to (12).
  • the ear bud or hearing aid of (15), comprising said adaptive device with two different SMPs each having a different glass transition temperature, wherein preferably the first SMP has a glass transition temperature close to body temperature (such as about 35°C to 45°C) and is located on the outside or the surface of the ear bud or hearing aid, and the second SMP has a glass transition temperature which is higher than the glass transition temperature of the first SMP (such as 45°C to 70°C) and is located inside the earing bud or hearing aid.
  • the first SMP has a glass transition temperature close to body temperature (such as about 35°C to 45°C) and is located on the outside or the surface of the ear bud or hearing aid
  • the second SMP has a glass transition temperature which is higher than the glass transition temperature of the first SMP (such as 45°C to 70°C) and is located inside the earing bud or hearing aid.
  • thermochromic pigment shows the temperature of the ear bud or hearing aid at a given moment to the user.
  • An adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive fabric of any one of (1) to (7) or at least one adaptive fabric obtained by a method of any one of (9) to (12).
  • thermochromic pigment shows the temperature at a given moment to the user or to a camera.
  • the present disclosure concerns customized adaptive objects which are produced via additive manufacturing techniques by using shape memory material as feed and can be implemented in various end use applications.
  • the key feature of these substances is that they can adapt and conform to a desired shape when they are heated above the glass transition temperature of the base materials. If optionally cooled down, the object becomes stiff, keeping the desired form. After release, the objects can be re-heated to both recover their initial shape and also to be soft to again reconform to the next desired form.
  • An additional feature is the thermochromic effect of the object, indicating visually whether it is in the heated or cold state. The visual indication giving useful feedback to the user interface.
  • the inventors have developed adaptive ear buds or hearing aids: [00116] Commercially available hearing aids and ear plugs products are not nicely fitting to every one’s ear, therefore a custom fit hearing aid that can be tailored more specifically for each individual needs is required.
  • the present disclosure provides a hearing aid and/or an ear bud which can adapt to different size and forms of ears because of the shape memory polymer used in it. Since the glass transition temperature of this material can be close to body temperature, they can adapt their form to each individual’s ears and make them as comfortable as possible. [00117] As a result of the adaptive fit of the hearing aids / ear buds of the present disclosure to different ear size and models, the wearer comfort is improved without necessity of product design for each individual.
  • the method of the present disclosure has the benefit of quickly print thin, flexible textiles composed of shape memory polymer filaments with an unmodified 3D printer setting.
  • the flexible, thin, and breathable properties of textiles are combined with the affordances of 3D printing combined with unique characteristic of shape memory polymers used as print materials. This enables tuning of the mechanical and aesthetic properties through material and parameter selection. It further allows to generate smart textiles with local characteristic of shape memory material which can switch between hard and soft accordance to user desire.
  • Figure 2 shows a 3D printed customizable ear bud as produced with a method of the present disclosure.
  • the ear bud model was modified with holes in the outer shell to enhance flexibility in the soft state and to allow for some breathability of the device.
  • Figure 2A shows the ear bud in its initial hard state with its initial color.
  • Figure 2B shows the ear bud after it was heated above the SMP’s glass transition temperature which is indicated by the change in color. In this state the device is soft and flexible and will morph its shape to fit any ear size.
  • Figure 3 shows part of a ⁇ 20cm wide piece of 3D printed textile as produced with a method of the present disclosure.
  • the textile is printed not on the XY plane but in Z direction. Furthermore, it was 3D printed in a circular pattern to allow for a larger textile to be produced on the small area of the build platform. After 3D printing, the circle can be cut open to give a textile sheet.
  • Figure 4A is a microscope image of the textile structure with a close-up view in Figure 4B.
  • the structure is a result of the combination of speed and under-extrusion. The density of the structure can be varied by altering these two parameters.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Textile Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Signal Processing (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Otolaryngology (AREA)
  • Neurosurgery (AREA)
  • General Health & Medical Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

The field of the DISCLOSURE lies in adaptive objects and materials for implementation in textiles, ear buds, wearables and smart clothing. The present disclosure relates to adaptive devices or fabrics, comprising shape memory polymer(s) and optionally thermochromic pigment(s), wherein the device or fabric is obtained by fused deposition molding and has different states it reversibly changes in between depending on heating. The present invention further relates to methods of producing said adaptive devices or fabrics. The present disclosure also relates to the use of said adaptive devices or fabrics, in particular, their use for customizable ear buds, semi-woven textiles, parts of smart textiles, wearables and/or gaming gloves and suits. The present disclosure also relates to an ear bud or hearing aid as well as to an adaptive semi-woven 3D printed textile or clothing item.

Description

CUSTOMIZED ADAPTIVE OBJECTS MADE BY ADDITIVE MANUFACTURING
BACKGROUND
[0001] The field of the DISCLOSURE lies in adaptive objects and materials for implementation in textiles, ear buds, wearables and smart clothing.
[0002] The present disclosure relates to adaptive devices or fabrics, comprising shape memory polymer(s) and optionally thermochromic pigment(s), wherein the device or fabric is obtained by fused deposition molding and has different states it reversibly changes in between depending on heating.
[0003] The present invention further relates to methods of producing said adaptive devices or fabrics.
[0004] The present disclosure also relates to the use of said adaptive devices or fabrics, in particular, their use for customizable ear buds, semi-woven textiles, parts of smart textiles, wearables and/or gaming gloves and suits.
[0005] The present disclosure also relates to an ear bud or hearing aid as well as to an adaptive semi-woven 3D printed textile or clothing item.
DESCRIPTION OF THE RELATED ART
[0006] The “background” description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description which may not otherwise qualify as prior art at the time of filing, are neither expressly or impliedly admitted as prior art against the present disclosure.
[0007] The research and applications of consumer products and textiles are directly related to the daily life of the social populace. However, some conventional products and textiles can no longer meet the requirements of intellectualization in modern society or the customer’s comfort needs.
[0008] For example, ears come in all shapes and sizes so there is not a one-size-fits-all hearing aid solution to the discomfort they cause. The commercially available hearing aids and ear plugs products are not nicely fitting to every one’s ear, therefore exploring a custom fit hearing aid that may be tailored more specifically for each individual needs is required.
[0009] Textile production industry is a matured technology with well-established techniques, however, bringing new function to textile by using more sustainable solution is still missing.
SUMMARY
[0010] In the following, the elements of the invention will be described. These elements are listed with specific embodiments, however, it should be understood that they may be combined in any manner and in any number to create additional embodiments. The variously described examples and preferred embodiments should not be construed to limit the present invention to only the explicitly described embodiments. This description should be understood to support and encompass embodiments which combine two or more of the explicitly described embodiments or which combine the one or more of the explicitly described embodiments with any number of the disclosed and/or preferred elements. Furthermore, any permutations and combinations of all described elements in this application should be considered disclosed by the description of the present application unless the context indicates otherwise.
[0011] The present disclosure provides an adaptive device or fabric comprising:
(i) a shape memory polymer (SMP) which has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, and which reversibly changes shape when heated above its glass transition temperature, and
(ii) optional, thermochromic pigment(s), wherein the device or fabric is obtained by fused deposition molding, preferably 3D printing, and wherein the device or fabric has different states it reversibly changes in between in dependence on said heating.
[0012] The present disclosure provides a method of producing an adaptive device according to the disclosure, comprising the steps:
(1) Extruding a SMP into a filament;
(2) Feeding the SMP filament into a 3D printer, wherein the 3D printer comprises:
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block;
(vi) a single printing nozzle, wherein the feeding tube connects the filament feeding gears with the heat break and passes through the cooler, wherein the heat break connects the cooler and the heating block, wherein the heating block connects the heat break and the single printing nozzle, and wherein thermally conductive paste is applied on the thread between the heat break and the cooler; and
(3) Printing the adaptive device from the single printing nozzle.
[0013] The present disclosure provides a method of producing an adaptive fabric according to the disclosure, comprising the steps:
(1) Extruding a SMP into a filament;
(2) Feeding the SMP filament into a 3D printer, wherein the 3D printer comprises:
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block;
(vi) a single printing nozzle, wherein the feeding tube connects the filament feeding gears with the heat break and passes through the cooler, wherein the heat break connects the cooler and the heating block, wherein the heating block connects the heat break and the single printing nozzle, and wherein thermally conductive paste is applied on the thread between the heat break and the cooler; and
(3) Printing the adaptive device from the single printing nozzle, wherein during printing the printing speed and/or the extrusion factor is modified in order to deliberately introduce defects into the printed fabric, which results in a textile structure which is flexible, bendable and/or stretchable.
[0014] The present disclosure provides an adaptive device or fabric obtained by a method of the present disclosure.
[0015] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in customizable ear buds.
[0016] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in customizable hearing aids.
[0017] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in semi-woven textiles.
[0018] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in clothing items.
[0019] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in parts of smart textiles.
[0020] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in wearables.
[0021] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in functional underwear.
[0022] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming gloves.
[0023] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming suits.
[0024] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming headsets.
[0025] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming chairs. [0026] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in gaming controllers.
[0027] The present disclosure provides an ear bud or hearing aid comprising at least one adaptive device of the present disclosure or an adaptive device obtained by a method of the present disclosure.
[0028] The present disclosure provides an adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive fabric of the present disclosure or an adaptive fabric obtained by a method of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0030] Figure 1 shows an adaptive device or fabric of the present disclosure and its possible reversible shape changes.
[0031] Figure 2 shows an ear bud as an adaptive device of the present disclosure. Figure 2A shows the ear bud in its initial hard state with its initial color. Figure 2B shows the ear bud in its programmed state. The color indicates that its temperature is above the SMP’s glass transition temperature. Figure 2C shows the ear bud as applied into the ear.
[0032] Figure 3 shows a textile which was obtained with the method of the present disclosure. [0033] Figure 4A shows a textile which was obtained with the method of the present disclosure. Figure 4B is a close-up of the textile of Figure 4A.
[0034] Figure 5 shows a 3D printer as used in the methods of the present disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0035] As discussed above, the present disclosure provides an adaptive device or fabric. Said adaptive device or fabric comprises
(i) a shape memory polymer (SMP), which has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, and which reversibly changes shape when heated above its glass transition temperature; and
(ii) optional, thermochromic pigment(s).
[0036] The adaptive device or fabric is obtained by fused deposition molding, preferably 3D printing.
[0037] Fused deposition modeling (FDM) is an additive manufacturing technology that belongs to the industrial 3D printing process. FDM creates 3D components using a continuous thermoplastic or composite material thread in filament form. The layout for FDM contains a printhead able to move along X and Z directions above a build platform which is able to move along the Y direction. FDM is sometimes also called fused filament fabrication (FFF).
[0038] The adaptive device or fabric has different states it reversibly changes in between in dependence on said heating. [0039] The shape memory polymer (SMP) (i) has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, preferably about 35°C to 45°C, more preferably about 35°C to 40°C. Preferably, the SMP has a glass transition temperature in the range of the body temperature.
[0040] In a preferred embodiment, the shape memory polymer (SMP) (i) is thermoplastic polyurethane (TPU). In one embodiment, the SMP is about 100% TPU.
[0041] In one embodiment, the shape memory polymer (SMP) does not contain polylactic acid (PL A), polyvinyl alcohol (PVA), polybutylene succinate (PBS) or acrylonitrile butadiene styrene (ABS).
[0042] In one embodiment, the adaptive device or fabric comprises more than one SMP, wherein each SMP has a different glass transition temperature.
[0043] In one embodiment, the adaptive device or fabric comprises up to five different SMPs. In one embodiment, the adaptive device or fabric comprises two different SMPs. In one embodiment, the adaptive device or fabric comprises three different SMPs. In one embodiment, the adaptive device or fabric comprises four different SMPs. In one embodiment, the adaptive device or fabric comprises five different SMPs.
[0044] In one embodiment, the heating is carried out passively, such as by body temperature. [0045] In one embodiment, the heating is carried out actively, preferably by a heating element. [0046] The heating element can be rigid. The heating element can be bendable or flexible. The heating element can be a wire.
[0047] In one embodiment, the heating element is printed together with the SMP.
[0048] The adaptive device or fabric has different states it reversibly changes in between in dependence on the heating.
[0049] In one embodiment, the different states are:
(a) a soft and flexible state, and
(b) a hard and less flexible state.
[0050] In one embodiment, the adaptive device or fabric acquires a desired shape, when cooled down, preferably below the glass transition temperature. It can be frozen into said desired shape. [0051] The cooling down can be carried out passively by convection, conduction or radiation. The cooling down can be carried out actively, preferably by a heating element, such as a Peltier element.
[0052] In one embodiment, the adaptive device or fabric returns to its initial state when it is reheated above its glass transition temperature.
[0053] In one embodiment, the adaptive device or fabric returns to its initial state, when it is reheated above its glass transition temperature, and it can then acquire a next /another desired shape.
[0054] In one embodiment, the adaptive device or fabric comprises one or more thermochromic pigments (ii). [0055] The thermochromic pigments are preferably selected from spirolactones, fluorans, spiropyrans, or fulgides compounds.
[0056] In one embodiment, the thermochromic pigment(s) are incorporated in a polymer matrix. For a better miscibility the thermochromic pigment is preferably not added as such but is included in a polymer matrix.
[0057] The polymer matrix can be a so-called thermochromic masterbatch (TCMB). The base polymer matrix, such as the TCMB, can be low-density polyethylene (LDPE) or thermoplastic polyurethane (TPU). The content of pigment is preferably in the range from about 20% to about 45%.
[0058] In one embodiment, the thermochromic pigment shows the temperature of the device or fabric at a given moment to the user and/or to a camera.
[0059] Such additional feature can also be called the thermochromic effect of the adaptive device or fabric. It indicates visually whether the adaptive device or fabric is in the heated or cold state. The visual indication gives useful feedback to the user interface.
[0060] As discussed above, the present disclosure provides a method of producing an adaptive device according to the disclosure.
[0061] Said method comprises the steps:
(1) Extruding a SMP into a filament;
(2) Feeding the SMP filament into a 3D printer; and
(3) Printing the adaptive device from the single printing nozzle.
[0062] In an embodiment, where thermochromic pigment(s) are included in the adaptive device, in step (1) a mixture is extruded into a filament, wherein said mixture comprises or consists of SMP and the thermochromic pigment(s), which is/are included or incorporated in a polymer matrix,
[0063] For example, it can be a mixture of about 90% to about 99% SMP(s) and about 1% to about 10% TCMB, preferably about 92% to about 98% SMP(s) and about 2% to about 8% TCMB, more preferably about 95% SMP(s) and about 5% TCMB.
[0064] The 3D printer which is used in step (2) comprises:
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block; and
(vi) a single printing nozzle.
[0065] The feeding tube connects the filament feeding gears with the heat break and passes through the cooler. The feeding tube ends where the heat break starts. The heat break connects the cooler and the heating block, wherein thermally conductive paste is applied on the thread between the heat break and the cooler. The heat break is the only connection between cooler and heating block. The heating block connects the heat break and the single printing nozzle. [0066] In one embodiment, the thermally conductive paste is only applied between the heat break and the cooler, and it is not applied between the heat break and the heating block.
[0067] For example, a suitable thermally conductive paste is a paste comprising carbon microparticles, e.g. MX-4 thermal paste (ARCTIC GmbH, Germany).
[0068] In one embodiment, up to five different SMPs are used. In this embodiment, in step (1) for each SMP a different filament is extruded. The different filaments are preferably fed together into one single feeding tube.
[0069] In one embodiment, the single printing nozzle has a diameter in the range from about 0.2 mm to about 1 mm. Examples for the diameter of the single printing nozzle are about 0.25 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm or about 0.8 mm.
[0070] In one embodiment, the heating break is made of titanium or a titanium alloy. For example, titanium Grade 5 (EN 3.7165 or Ti Gr 5 / 3.7165).
[0071] As discussed above, the present disclosure provides a method of producing an adaptive fabric according to the disclosure.
[0072] Said method comprises the steps:
(1) Extruding a SMP into a filament;
(2) Feeding the SMP filament into a 3D printer; and
(3) Printing the adaptive device from the single printing nozzle.
[0073] During printing in step (3), the printing speed and/or the extrusion factor is modified in order to deliberately introduce defects into the printed fabric. This modification results in a textile structure which is flexible, bendable and/or stretchable.
[0074] The printing speed can be modified, for example, between 25 and 200mm/2.
[0075] The extrusion factor can be modified, for example, by 0.3-0.8 or 30-80%.
[0076] In an embodiment, where thermochromic pigment(s) are included in the adaptive device, in step (1) a mixture is extruded into a filament, wherein said mixture comprises or consists of SMP and the thermochromic pigment(s), which is/are included or incorporated in a polymer matrix,
[0077] For example, it can be a mixture of about 90% to about 99% SMP(s) and about 1% to about 10% TCMB, preferably about 92% to about 98% SMP(s) and about 2% to about 8% TCMB, more preferably about 95% SMP(s) and about 5% TCMB.
[0078] The 3D printer which is used in step (2) comprises:
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block; and
(vi) a single printing nozzle. [0079] The feeding tube connects the filament feeding gears with the heat break and passes through the cooler. The feeding tube ends where the heat break starts. The heat break connects the cooler and the heating block, wherein thermally conductive paste is applied on the thread between the heat break and the cooler. The heat break is the only connection between cooler and heating block. The heating block connects the heat break and the single printing nozzle.
[0080] In one embodiment, the thermally conductive paste is only applied between the heat break and the cooler, and it is not applied between the heat break and the heating block.
[0081] For example, a suitable thermally conductive paste is a paste comprising carbon microparticles, e.g. MX-4 thermal paste (ARCTIC GmbH, Germany).
[0082] In one embodiment, up to five different SMPs are used. In this embodiment, in step (1) for each SMP a different filament is extruded. The different filaments are preferably fed together into one single feeding tube.
[0083] In one embodiment, the single printing nozzle has a diameter in the range from about 0.2 mm to about 1 mm. Examples for the diameter of the single printing nozzle are about 0.25 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm or about 0.8 mm.
[0084] In one embodiment, the heating break is made of titanium or a titanium alloy. For example, titanium Grade 5 ( EN 3.7165 or Ti Gr 5 / 3.7165).
[0085] As discussed above, the present disclosure provides an adaptive device or fabric obtained by a method of the present disclosure.
[0086] As discussed above, the present disclosure provides the use of the adaptive device or fabric the present disclosure, or the adaptive device or fabric obtained by a method of the present disclosure. In particular:
[0087] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in customizable ear buds.
[0088] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in customizable hearing aids.
[0089] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in semi-woven textiles.
[0090] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in clothing items.
[0091] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure in parts of smart textiles. [0092] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for/in wearables.
[0093] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for functional underwear.
[0094] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming gloves.
[0095] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming suits.
[0096] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming headsets.
[0097] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming chairs.
[0098] The present disclosure provides the use of an adaptive device or fabric of the present disclosure, or an adaptive device or fabric obtained by a method of the present disclosure for gaming controllers.
[0099] As discussed above, the present disclosure provides an ear bud or hearing aid comprising at least one adaptive device of the present disclosure.
[00100] As discussed above, the present disclosure provides an ear bud or hearing aid comprising at least one adaptive device obtained by a method of the present disclosure.
[00101] In one embodiment, the ear bud or hearing aid comprises said adaptive device with two different SMPs each having a different glass transition temperature.
[00102] In this embodiment, the first SMP has a glass transition temperature close to body temperature, such as about 35 to 45°C. The first SMP is located on the outside or the surface of the ear bud or hearing aid.
[00103] In this embodiment, the second SMP has a glass transition temperature which is higher than the glass transition temperature of the first SMP, such as 45 to 70°C. The second SMP is preferably located inside the earing bud or hearing aid.
[00104] In one embodiment, the ear bud or hearing aid comprises a thermochromic pigment. The thermochromic pigment preferably shows the temperature of the ear bud or hearing aid at a given moment to the user.
[00105] As discussed above, the present disclosure provides an adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive device of the present disclosure. [00106] As discussed above, the present disclosure provides adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive device obtained by a method of the present disclosure.
[00107] In one embodiment, the textile or clothing item comprises said adaptive fabric with two different SMPs each having a different glass transition temperature.
[00108] In one embodiment, the textile or clothing item comprises more than one adaptive fabric.
[00109] In one embodiment, the textile or clothing item comprises local areas comprising the adaptive fabric.
[00110] In one embodiment, the textile or clothing item does not comprise natural fibers, such as wool or cotton, and/or polyester or polyamide.
[00111] In one embodiment, the textile or clothing item comprises a thermochromic pigment. The thermochromic pigment preferably shows the temperature of the ear bud or hearing aid at a given moment to the user or to a camera.
[00112] Note that the present technology can also be configured as described below.
(1) An adaptive device or fabric comprising
(i) a shape memory polymers (SMP), which has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, preferably about 35°C to 45°C, more preferably about 35°C to 40°C, and which reversibly changes shape when heated above its glass transition temperature, and
(ii) optional, thermochromic pigment(s), wherein the device or fabric is obtained by fused deposition molding, preferably 3D printing, and wherein the device or fabric has different states it reversibly changes in between in dependence on said heating, preferably a soft and flexible state and a hard and less flexible state.
(2) The adaptive device or fabric of (1), wherein the shape memory polymer (SMP) is thermoplastic polyurethane (TPU) (such as 100% TPU), and wherein the shape memory polymer (SMP) preferably does not contain polylactic acid
(PL A), polyvinyl alcohol (PVA), polybutylene succinate (PBS) or acrylonitrile butadiene styrene (ABS).
(3) The adaptive device or fabric of (1) or (2), comprising more than one SMP, such as up to five SMPs, wherein each SMP has a different glass transition temperature.
(4) The adaptive device or fabric of any one of (1) to (3), wherein the heating is carried out passively, such as by body temperature, or wherein the heating is carried out actively, preferably by a heating element.
(5) The adaptive device or fabric of (4), wherein the heating element is rigid or bendable/flexible or is a wire, and/or wherein the heating element is printed together with the SMP.
(6) The adaptive device or fabric of any one of (1) to (5), wherein the adaptive device or fabric when cooled down acquires a desired shape, and can be frozen into said desired shape, and/or wherein the adaptive device or fabric when re-heated above its glass transition temperature returns to its initial state.
(7) The adaptive device or fabric of any one of (1) to (6), wherein the thermochromic pigment(s) is/are selected from spirolactones, fluorans, spiropyrans, or fulgides compounds, wherein the thermographic pigment(s) is/are preferably incorporated in a polymer matrix, and/or wherein the thermochromic pigment shows the temperature of the device or fabric at a given moment to the user.
(8) A method of producing an adaptive device according to any one of (1) to (7), comprising the steps:
(1) Extruding a SMP into a filament; or optionally extruding a mixture of about 90% to about 99% SMP and about 1% to about 10% thermographic pigment(s) incorporated in a polymer matrix;
(2) Feeding the SMP filament into a 3D printer, wherein the 3D printer comprises:
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block;
(vi) a single printing nozzle, wherein the feeding tube connects the filament feeding gears with the heat break and passes through the cooler and wherein the heat break connects the cooler and the heating block and wherein the heating block connects the heat break and the single printing nozzle, and wherein thermally conductive paste is applied on the thread between the heat break and the cooler; and
(3) Printing the adaptive device from the single printing nozzle.
(9) A method of producing an adaptive fabric according to any one of (1) to (7), comprising the steps:
(1) Extruding a SMP into a filament; or optionally extruding a mixture of about 90% to about 99% SMP and about 1% to about 10% thermographic pigment(s) incorporated in a polymer matrix;
(2) Feeding the SMP filament into a 3D printer, wherein the 3D printer comprises:
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block;
(vi) a single printing nozzle, wherein the feeding tube connects the filament feeding gears with the heat break and passes through the cooler and wherein the heat break connects the cooler and the heating block and wherein the heating block connects the heat break and the single printing nozzle, and wherein thermally conductive paste is applied on the thread between the heat break and the cooler; and (3) Printing the adaptive fabric from the single printing nozzle, wherein during printing the printing speed and/or the extrusion factor is modified in order to deliberately introduce defects into the printed fabric, which results in a textile structure which is flexible, bendable and/or stretchable.
(10) The method of (8) or (9), wherein different SMPs are used, and wherein for each SMP a different filament is extruded, and the different filaments are preferably fed together into one single feeding tube.
(11) The method of any one of (8) to (10), wherein the single printing nozzle has a diameter in the range from about 0.2 mm to about 1 mm, such as about 0.25, 0.4, 0.5, 0.6 or 0.8 mm.
(12) The method of any one of (8) to (11), wherein the heating break is made of titanium or a titanium alloy.
(13) An adaptive device or fabric obtained by a method of any one of (8) to (12).
(14) Use of the adaptive device or fabric of any one of (1) to (7), or the adaptive device or fabric obtained by a method of any one of (8) to (12) for/in:
- customizable ear buds,
- customizable hearing aids,
- semi-woven textiles,
- clothing items,
- parts of smart textiles,
- wearables,
- functional underwear,
- gaming gloves,
- gaming suits,
- gaming headsets,
- gaming chairs,
- gaming controllers.
(15) An ear bud or hearing aid comprising at least one adaptive device of any one of (1) to (7) or obtained by a method of any one of (8), (10) to (12).
(16) The ear bud or hearing aid of (15), comprising said adaptive device with two different SMPs each having a different glass transition temperature, wherein preferably the first SMP has a glass transition temperature close to body temperature (such as about 35°C to 45°C) and is located on the outside or the surface of the ear bud or hearing aid, and the second SMP has a glass transition temperature which is higher than the glass transition temperature of the first SMP (such as 45°C to 70°C) and is located inside the earing bud or hearing aid.
(17) The ear bud or hearing aid of (15) or (16), wherein the thermochromic pigment shows the temperature of the ear bud or hearing aid at a given moment to the user.
(18) An adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive fabric of any one of (1) to (7) or at least one adaptive fabric obtained by a method of any one of (9) to (12). (19) The textile or clothing item of (18), comprising said adaptive fabric with two different SMPs each having a different glass transition temperature, or comprising more than one adaptive fabric.
(20) The textile or clothing item of (18) or (19), which comprises local areas comprising the adaptive fabric.
(21) The textile or clothing item of any one of (18) to (20), which does not comprise natural fibers, such as wool or cotton, and/or polyester or polyamide.
(22) The textile or clothing item of any one of (18) to (21), wherein the thermochromic pigment shows the temperature at a given moment to the user or to a camera.
[00113] The adaptive devices and fabrics made by additive manufacturing with advantageous features have been explored and developed by the present inventors.
[00114] The present disclosure concerns customized adaptive objects which are produced via additive manufacturing techniques by using shape memory material as feed and can be implemented in various end use applications. The key feature of these substances is that they can adapt and conform to a desired shape when they are heated above the glass transition temperature of the base materials. If optionally cooled down, the object becomes stiff, keeping the desired form. After release, the objects can be re-heated to both recover their initial shape and also to be soft to again reconform to the next desired form. An additional feature is the thermochromic effect of the object, indicating visually whether it is in the heated or cold state. The visual indication giving useful feedback to the user interface.
[00115] In particular, the inventors have developed adaptive ear buds or hearing aids: [00116] Commercially available hearing aids and ear plugs products are not nicely fitting to every one’s ear, therefore a custom fit hearing aid that can be tailored more specifically for each individual needs is required. The present disclosure provides a hearing aid and/or an ear bud which can adapt to different size and forms of ears because of the shape memory polymer used in it. Since the glass transition temperature of this material can be close to body temperature, they can adapt their form to each individual’s ears and make them as comfortable as possible. [00117] As a result of the adaptive fit of the hearing aids / ear buds of the present disclosure to different ear size and models, the wearer comfort is improved without necessity of product design for each individual. Moreover, by using electro thermal elements, switchability of the hearing aids between soft and rigid, fitting and fixing can be easily performed. Moreover, the color change effect increases the UX values as the function change can be immediately visually observed. Furthermore, different shape memory materials with modified characteristics can be used to meet different criteria. In addition, variable acoustic characterization also can be achieved based on shape memory polymer.
[00118] In particular, the inventors have developed adaptive semi-woven SMP textiles: [00119] Textile production industry is a matured technology with well-established techniques, however, bringing new function to textile by using more sustainable solution is still missing. By using additive manufacturing technologies, processes can use less raw materials, chemicals, and water, and in addition, the amount of waste materials produced is significantly minimized. Other advantages of 3D printing technique include reduced energy needs and consequent carbon emissions, cost savings, and extremely enhanced design freedom. Design freedom also includes freedom in material selection used for 3D printing technique like functional material. In the present disclosure, the inventors used Fused Deposition Modeling (FDM) as the most common and inexpensive approach for 3D printing and shape memory filament as print material. Here we showed that some deliberately applied defects can be set in print parameters in the software to print thin and flexible semi-woven textile based on shape memory polymers which show variable softness characteristic based on user demand.
[00120] The method of the present disclosure has the benefit of quickly print thin, flexible textiles composed of shape memory polymer filaments with an unmodified 3D printer setting. In the method of the present disclosure, the flexible, thin, and breathable properties of textiles are combined with the affordances of 3D printing combined with unique characteristic of shape memory polymers used as print materials. This enables tuning of the mechanical and aesthetic properties through material and parameter selection. It further allows to generate smart textiles with local characteristic of shape memory material which can switch between hard and soft accordance to user desire.
EXAMPLES
EXAMPLE 1 : Customizable ear bud
[00121] Figure 2 shows a 3D printed customizable ear bud as produced with a method of the present disclosure. The ear bud model was modified with holes in the outer shell to enhance flexibility in the soft state and to allow for some breathability of the device. Figure 2A shows the ear bud in its initial hard state with its initial color. Figure 2B shows the ear bud after it was heated above the SMP’s glass transition temperature which is indicated by the change in color. In this state the device is soft and flexible and will morph its shape to fit any ear size.
Furthermore, it will keep its form if it is cooled down which is shown in Figure 2C where the ear bud was applied into an ear model. The shape of the ear bud was frozen to keep the best fit which is indicated by the change to the initial color.
EXAMPLE 2: 3D printed textiles
[00122] Figure 3 shows part of a ~20cm wide piece of 3D printed textile as produced with a method of the present disclosure. The textile is printed not on the XY plane but in Z direction. Furthermore, it was 3D printed in a circular pattern to allow for a larger textile to be produced on the small area of the build platform. After 3D printing, the circle can be cut open to give a textile sheet. Figure 4A is a microscope image of the textile structure with a close-up view in Figure 4B. The structure is a result of the combination of speed and under-extrusion. The density of the structure can be varied by altering these two parameters.
[00123] The features of the present disclosure disclosed in the specification, the claims, and/or in the accompanying figures may, both separately and in any combination thereof, be material for realizing the disclosure in various forms thereof. Thus, the foregoing discussion discloses and describes merely exemplary embodiments of the present disclosure. As will be understood by those skilled in the art, the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present disclosure is intended to be illustrative, but not limiting of the scope of the disclosure, as well as other claims. The disclosure, including any readily discernible variants of the teachings herein, define, in part, the scope of the foregoing claim terminology such that no inventive subject matter is dedicated to the public.

Claims

1. An adaptive device or fabric comprising
(i) a shape memory polymer (SMP) which has a glass transition temperature (Tg) in the range from about 25°C to about 50°C, preferably about 35°C to 45°C, more preferably about 35°C to 40°C, and which reversibly changes shape when heated above its glass transition temperature, and
(ii) optional, thermochromic pigment(s), wherein the device or fabric is obtained by fused deposition molding, preferably 3D printing, and wherein the device or fabric has different states it reversibly changes in between in dependence on said heating, preferably a soft and flexible state and a hard and less flexible state.
2. The adaptive device or fabric of claim 1, wherein the shape memory polymer (SMP) is thermoplastic polyurethane (TPU) (such as 100% TPU), and wherein the shape memory polymer (SMP) preferably does not contain polylactic acid (PLA), polyvinyl alcohol (PVA), polybutylene succinate (PBS) or acrylonitrile butadiene styrene (ABS).
3. The adaptive device or fabric of claim 1 or 2, comprising more than one SMP, such as up to five SMPs, wherein each SMP has a different glass transition temperature.
4. The adaptive device or fabric of any one of claims 1 to 3, wherein the heating is carried out passively, such as by body temperature, or wherein the heating is carried out actively, preferably by a heating element.
5. The adaptive device or fabric of claim 4, wherein the heating element is rigid or bendable/flexible or is a wire, and/or wherein the heating element is printed together with the SMP.
6. The adaptive device or fabric of any one of claims 1 to 5, wherein the adaptive device or fabric when cooled down acquires a desired shape, and can be frozen into said desired shape, and/or wherein the adaptive device or fabric when re-heated above its glass transition temperature returns to its initial state.
7. The adaptive device or fabric of any one of claims 1 to 6, wherein the thermochromic pigment(s) is/are selected from spirolactones, fluorans, spiropyrans, or fulgides compounds, wherein the thermographic pigment(s) is/are preferably incorporated in a polymer matrix. and/or wherein the thermochromic pigment shows the temperature of the device or fabric at a given moment to the user.
8. A method of producing an adaptive device according to any one of claims 1 to 7, comprising the steps:
(1) Extruding a SMP into a filament; or optionally extruding a mixture of about 90% to about 99% SMP and about 1% to about 10% thermographic pigment(s) incorporated in a polymer matrix;
(2) Feeding the SMP filament into a 3D printer; wherein the 3D printer comprises:
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block;
(vi) a single printing nozzle, wherein the feeding tube connects the filament feeding gears with the heat break and passes through the cooler and wherein the heat break connects the cooler and the heating block and wherein the heating block connects the heat break and the single printing nozzle, and wherein thermally conductive paste is applied on the thread between the heat break and the cooler; and
(3) Printing the adaptive device from the single printing nozzle.
9. A method of producing an adaptive fabric according to any one of claims 1 to 7, comprising the steps:
(1) Extruding a SMP into a filament; or optionally extruding a mixture of about 90% to about 99% SMP and about 1% to about 10% thermographic pigment(s) incorporated in a polymer matrix;
(2) Feeding the SMP filament into a 3D printer; wherein the 3D printer comprises
(i) filament feeding gears;
(ii) a feeding tube;
(iii) a cooler;
(iv) a heat break;
(v) a heating block;
(vi) a single printing nozzle, wherein the feeding tube connects the filament feeding gears with the heat break and passes through the cooler and wherein the heat break connects the cooler and the heating block and wherein the heating block connects the heat break and the single printing nozzle, and wherein thermally conductive paste is applied on the thread between the heat break and the cooler; and
(3) Printing the adaptive fabric from the single printing nozzle, wherein during printing the printing speed and/or the extrusion factor is modified in order to deliberately introduce defects into the printed fabric, which results in a textile structure which is flexible, bendable and/or stretchable.
10. The method of claim 8 or 9, wherein different SMPs are used, and wherein for each SMP a different filament is extruded, and the different filaments are preferably fed together into one single feeding tube.
11. The method of any one of claims 8 to 10, wherein the single printing nozzle has a diameter in the range from about 0.2 mm to about 1 mm, such as about 0.25, 0.4, 0.5, 0.6 or 0.8 mm.
12. The method of any one of claims 8 to 11, wherein the heating break is made of titanium or a titanium alloy.
13. An adaptive device or fabric obtained by a method of any one of claims 8 to 12.
14. Use of the adaptive device or fabric of any one of claims 1 to 7, or the adaptive device or fabric obtained by a method of any one of claims 8 to 12 for/in:
- customizable ear buds,
- customizable hearing aids,
- semi-woven textiles,
- clothing items,
- parts of smart textiles,
- wearables,
- functional underwear,
- gaming gloves,
- gaming suits,
- gaming headsets,
- gaming chairs,
- gaming controllers.
15. An ear bud or hearing aid comprising at least one adaptive device of any one of claims 1 to 7 or obtained by a method of any one of claims 8, 10 to 12.
16. The ear bud or hearing aid of claim 15, comprising said adaptive device with two different SMPs each having a different glass transition temperature, wherein preferably the first SMP has a glass transition temperature close to body temperature (such as about 35°C to 45°C) and is located on the outside or the surface of the ear bud or hearing aid and the second SMP has a glass transition temperature which is higher than the glass transition temperature of the first SMP (such as 45°C to 70°C) and is located inside the earing bud or hearing aid.
17. The ear bud or hearing aid of claim 15 or 16, wherein the thermochromic pigment shows the temperature of the ear bud or hearing aid at a given moment to the user.
18. An adaptive semi-woven 3D printed textile or clothing item comprising at least one adaptive fabric of any one of claims 1 to 7 or at least one adaptive fabric obtained by a method of any one of claims 9 to 12.
19. The textile or clothing item of claim 18, comprising said adaptive fabric with two different SMPs each having a different glass transition temperature, or comprising more than one adaptive fabric.
20. The textile or clothing item of claim 18 or 19, which comprises local areas comprising the adaptive fabric.
21. The textile or clothing item of any one of claims 18 to 20, which does not comprise natural fibers, such as wool or cotton, and/or polyester or polyamide.
22. The textile or clothing item of any one of claims 18 to 21, wherein the thermochromic pigment shows the temperature at a given moment to the user or to a camera.
EP24701991.2A 2023-03-30 2024-01-30 Personalized adaptive objects produced through additive manufacturing Pending EP4669513A1 (en)

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WO2018067918A2 (en) * 2016-10-06 2018-04-12 University Of Maryland, College Park Metal fiber composite additive manufacturing (mfc-am) and composite structures formed by mfc-am
US11014297B2 (en) * 2017-02-11 2021-05-25 Jared Robert Printing assembly for three-dimensional prototyping
US20200237378A1 (en) * 2019-01-25 2020-07-30 The Board Of Regents Of The University Of Oklahoma Shape memory polymer-based devices and methods of use in treating intracorporeal defects
US11839491B2 (en) * 2019-10-07 2023-12-12 The Regents Of The University Of Colorado, A Body Corporate Shape-memory in-ear biosensor for monitoring physiological signals
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