WO2024099488A1 - Matériau imprimé en 3d doté d'une structure interne souple de manière variable, en particulier pour la production d'équipement de sport - Google Patents

Matériau imprimé en 3d doté d'une structure interne souple de manière variable, en particulier pour la production d'équipement de sport Download PDF

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Publication number
WO2024099488A1
WO2024099488A1 PCT/CZ2023/050078 CZ2023050078W WO2024099488A1 WO 2024099488 A1 WO2024099488 A1 WO 2024099488A1 CZ 2023050078 W CZ2023050078 W CZ 2023050078W WO 2024099488 A1 WO2024099488 A1 WO 2024099488A1
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WIPO (PCT)
Prior art keywords
rods
referential
centre
face
cells
Prior art date
Application number
PCT/CZ2023/050078
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English (en)
Inventor
Jiri DUZAR
Martin RIPA
Petr Vacek
Original Assignee
Posedla s.r.o.
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.)
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Publication date
Application filed by Posedla s.r.o. filed Critical Posedla s.r.o.
Publication of WO2024099488A1 publication Critical patent/WO2024099488A1/fr

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62JCYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
    • B62J1/00Saddles or other seats for cycles; Arrangement thereof; Component parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00Soles; Sole-and-heel integral units
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • B29C64/153Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/14Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02Physical, chemical or physicochemical properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00Products made by additive manufacturing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16FSPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F2224/00Materials; Material properties
    • F16F2224/02Materials; Material properties solids
    • F16F2224/0225Cellular, e.g. microcellular foam

Definitions

  • the invention relates to the field of additive manufacturing by layering, specifically 3D printing, and materials and products manufactured in this way, in particular for use in sports equipment, especially bicycle saddles and plastic handlebar grips.
  • a typical example can be bicycle saddles, where their production is tailored to an individual according to the spacing of his sit bones, shape of the buttocks, and the distribution of weight while sitting. This leads to an increase in comfort while riding, which also positively affects the resulting sports performance.
  • document WO2019058183 describes a system of a bicycle saddle made of thermoplastic material, the shape of which can be customized by the rider himself using heat forming
  • document US2007273185 describes a method of adjusting the saddle according to the anatomy of the rider and a system for its implementation using a background impression and measuring the distance of the sit bones.
  • the ideal production procedure is the method of additive 3D printing.
  • Softness and flexibility are key features for a number of sports aids, for example the aforementioned bicycle saddles, handlebar grips, or shoes.
  • the softness of 3D printed objects can be achieved simply by using an elastic starting material, for example thermoplastic polyurethane, as known from document US2020046062. More advantageous properties in the form of a material providing higher user comfort can be achieved by combining an elastic starting material and a structured infill, as is known for example from documents US2020281310 and CN208783842.
  • Such an infill structure can be, for example, a honeycomb, which, however, provides additional flexibility only on the sides of the hexagonal structure, which does not allow for the construction of practically applicable flexible products of complicated shape, such as bicycle saddles, which also applies to grid infills in the shape of squares, triangles, stars, Hilbert curves, or spirals.
  • infill Other known types of infill are crystalline diamond lattices, which is, however, characterized by high spatial stiffness, and is therefore not suitable for flexible applications; gyroids, which are, however, too rigid and generally do not provide the resulting flexibility sufficient for use in sports equipment; Weaire-Phelan structures, which are only suitable for a very limited number of types of 3D printing and have limited resistance at the interface with other materials; or structures based on the Voronoi diagram, which, however, is derived from the random position of points in space, and therefore does not allow to effectively control the resulting flexibility of the printed material. Additionally, the described approaches generally do not allow a creation of products with areas of different stiffness.
  • Document CN111251641 describes a shoe sole made of 3D printed elastic material, where different stiffness in individual parts of the sole is achieved by changing the shape, structure, and orientation of the filling.
  • this approach does not allow for a continuous change in the material properties of the product.
  • a change in stiffness is achieved only to a specific, precisely defined value with a severely limited number of variants.
  • such a fundamental change in the internal structure, and thus also in the production process combined with a change in the stiffness of individual parts of the product limits, and practically prevents, the use of this technology for the production of individualized sports equipment.
  • a 3D printed material with an orthogonal internal structure is known from the prior art, where the structure is formed by rods mutually perpendicular in three axes defining a cube as a spatial unit, which enables continuous and localised scaling of the bending stiffness of the resulting material.
  • orthogonal structures albeit made of flexible materials, are locally too rigid both in the axial and diagonal direction and do not allow springing. Therefore, they are not suitable for applications requiring softness, such as the aforementioned bicycle saddles, handlebar grips, or shoe soles.
  • Goal of the present invention is to eliminate the shortcomings of the current prior art by introducing a material whose internal structure allows for continuous scaling of its softness and flexibility, and thus allows for manufacturing of integral products with areas or sections of different softness without the need for local or overall changes in the chemical composition of the starting raw materials or modification of the external dimensions and shape of the product. Such properties facilitate the manufacturing of individualized sports equipment using the method of 3D printing.
  • the present invention is based on a 3D-printed flexible material with an internal structure defined by cells elastic in the z-axis—which is defined in products made of this material as the axis parallel to the vector of the pressure force acting within the intended use of the product— where the stiffness of the cells in this axis is continuously scalable by changing the thickness of rods forming the structure of the individual cell. Assembling these cells into a plane creates a material with locally variable softness and flexibility, where the resolution of this change in material properties is determined by the dimensions of individual cells.
  • the cell consists of two parts, which are both derived from a spatially transformed cube and both have specifically defined internal structure different from each other. These parts are referred to as the A-type cuboid and the B-type cuboid.
  • rods lead from the centre of the referential top face to the centre of each referential vertical edge, while each of the rods is in contact with both respective faces that are meeting in that edge, and further, rods lead from the centre of the referential bottom face to the centre of each referential vertical edge, while each of the rods is in contact with both respective faces that are meeting in that edge.
  • the centres of the referential vertical edges of the A-type cuboid are in all embodiments shared by four cells, while the rods that lead to a given centre are connected to each other.
  • this face contains rods leading from the face’s centre to the face’s vertices, while these rods are connected in the centre.
  • the vertices of the referential top face of the A-type cuboid are in such cases in all embodiments shared by four cells, while the rods that lead to a given vertex are connected to each other.
  • rods lead from the centre of the referential top face to each vertex of the reference bottom face, while each of the rods is in contact with the referential bottom face.
  • the vertices of the referential bottom face of the B-type cuboid are shared by at least four cells, while the rods that lead to a given vertex are connected to each other.
  • this face contains rods leading from the face’s centre to the face’s vertices, while these rods are connected in the centre.
  • the vertices of the referential bottom face of the B-type cuboid are in such cases in all embodiments shared by four cells, while the rods that lead to a given vertex are connected to each other.
  • the B-type cuboid contains only two rods, namely the rods leading from the centre of the referential top face to the vertices of the referential bottom face that are internal from the point of view of the object, while each of the rods is in contact with the referential bottom face, and further, for the respective A-type cuboids forming the surface of the object, the rods of the referential top face do not lead to the vertices of the referential top face that are external from the point of view of the object, but only to the vertices of the referential top face that are internal from the point of view of the object, while said rods lead from the centre of the referential top face where they are connected to each other, and further, there are no rods in the referential bottom face of the respective B-type cuboids forming the surface of the object.
  • Cell of a basic configuration consisting of an A-type cuboid and a B-type cuboid can be further extended by additional layers of cuboids.
  • the ideal initial cuboid of both types is an orthogonal cube with edge length D and eight vertices A1 to A8 , while the cuboids can be arbitrarily transformed by shifting one or more vertices in a vector V , or more specifically vectors V1 to V8 for the respective vertices. These vectors can have any direction and their absolute values are smaller or equal to D .
  • the shape of the cuboids is selected at specific points of the object created from the material according to the present invention in terms of the shape and curvature of the object in the given place, while this shape directly affects the behaviour of the flexible structure. These properties are mainly influenced by the degree of deformation of the cube in all directions and its total volume.
  • the main parameter that affects the resulting stiffness of the structure in its individual parts is the thickness of the rods.
  • Lower thickness leads to a softer texture and vice versa.
  • the lower limit of thickness is determined by the functional limitation of the printing technology and is 1 mm for the thinnest parts.
  • the upper limit represents a state where excessive rod thickness deforms the geometry into a non-functional state, which is a state where the internal cell structure is fully filled with the rod material, leaving no room for springing.
  • the lower limit value of the thickness of the rods is 1 mm, values between 1.3 mm and 1.5 mm lead to a subjectively soft material, and values between 1.5 mm and 1.7 mm lead to a subjectively harder flexible material. At values above 1.7 mm, the material loses its elasticity.
  • the material according to the invention can be produced using any of the available methods of 3D printing.
  • the best results are achieved by the powder-bed 3D printing method, as there is no need to build external supports and the part is printed exactly according to the 3D model, including overhanging or spaced parts.
  • the ideal material is thermoplastic polyurethane (TPU), which enables subsequent vaporization, i.e. , a chemical treatment of the surface after printing, which further improves its properties and enables dyeing.
  • TPU thermoplastic polyurethane
  • it shows resistance to water or mechanical straining, good stability and resistance in a wide range of temperatures, and it is a material that does not suffer from a memory effect, i.e. , it does not change its original shape even after long-term loading.
  • FIG. 1 depicts a flexible cell, which is the basic unit of the material according to the present invention.
  • the rods are shown in a flat form.
  • the cell in this configuration consists of an A-type cuboid at the top and a B-type cuboid at the bottom.
  • FIG. 1 depicts a flexible cell (left) connected to a cell lying on the edge of an object made of the material according to the present invention (right).
  • the rods are shown in a flat form.
  • the cells in this configuration consist of an A-type cuboid at the top and a B-type cuboid at the bottom.
  • FIG. 1 depicts a cross-section of a bicycle saddle made of the material according to the invention.
  • FIG. 1 depicts a cross-section of a bicycle saddle made of the material according to the invention.
  • FIG. 1 depicts a handlebar grip made of the material according to the invention.
  • Example 1 depicts a bicycle saddle according to Example 1 with visible smoothed rods and dimensions of the saddle given in millimetres.
  • Example 1 depicts a bicycle saddle according to Example 1 with visible cuboids and dimensions of the saddle given in millimetres.
  • Example 1 depicts a section of a bicycle saddle according to Example 1 with visible cuboids and their dimensions in millimetres.
  • Example 1 depicts a cross-section of a section of a bicycle saddle according to Example 1 with visible cuboids and their dimensions in millimetres.
  • Example 2 depicts a handlebar grip according to Example 2 with visible smoothed rods and dimensions of the grip given in millimetres.
  • Example 2 depicts a cross-section of a handlebar grip according to Example 2 with visible smoothed rods and dimensions of the cells given in millimetres.
  • Example 1 describes a bicycle saddle with areas of different softness made of the material according to the present invention.
  • the material adapted to the shape of a bicycle saddle consists of cells formed by two parts, which are A-type cuboid 1 and B-type cuboid 2 .
  • the cells are arranged in one layer and are of two types: cells 3 of the inner part of the saddle and cells 4 of the edge of the saddle.
  • rods 5 lead from the centre 111 of the referential top face 11 to the centre 121 of each referential vertical edge 12 , with each of the rods 5 being in contact with both respective referential faces 13 of the given edge 12 , and further, rods 5 lead from the centre 141 of the referential bottom face 14 to the centre 121 of each referential vertical edge 12 , with each of the rods 5 being in contact with both respective referential faces 13 of the given edge 12 .
  • Centres 121 of the referential vertical edges 12 are shared by four cells, while rods 5 that lead to a given centre 121 are connected to each other.
  • the referential top face 11 forms the surface of the upper, i.e.
  • the face 11 contains rods 5 leading from the centre 111 to vertices 112 and the rods 5 are connected to each other in the centre 111 .
  • Vertices 112 are shared by four cells, while rods 5 that lead to a given vertex 112 are connected to each other.
  • rods 5 lead from the centre 211 of the referential top face 21 to each vertex 222 of the referential bottom face 22 , with each of the rods 5 being in contact with the referential bottom face 22 .
  • the vertices 222 of the referential bottom face 22 are shared by four cells, while rods 5 that lead to a given vertex 222 are connected to each other.
  • the referential bottom face 22 forms the surface of the underside of the saddle and as such, the face 22 contains rods 5 leading from the centre 221 to the vertices 222 and the rods 5 are connected to each other in the centre 221 .
  • Vertices 222 are shared by four cells, while rods 5 that lead to a given vertex 222 are connected to each other.
  • the structure of the A-type cuboid 1 of the cells 4 of the edge of the saddle is identical to the A-type cuboid 1 of the cells 3 of the inner part of the saddle with the difference that the referential top face 11 contains only two rods 5 leading from the centre 111 to the vertices 112 that are located inside the saddle, the rods 5 are connected to each other in the centre 111 , and each rod 5 is connected to other rods 5 that lead to a given vertex 112 .
  • the edge of the saddle is further equipped with a skirt 6 with a cross-section in the shape of the letter "L".
  • the material based on the structure described above is adapted to the shape of a bicycle saddle by a 3D-printing method based on laser sintering of a powder layer in a powder bed of a thermoplastic polyurethane.
  • the saddle has a total width of 142 mm and a total length of 254 mm, the width of the sitting part 7 is 49 mm, the width of the front transition part 8 is 23 mm, the width of the tip 9 is 51 mm, and the length of the tip 9 is 70 mm.
  • the underside of the saddle is also equipped with carbon-fibre skids, which allow it to be mounted on a bicycle.
  • the cuboids of the cells that make up the saddle have the shape of geometrically transformed cubes, while the lengths of their edges range from 4.3 mm to 8.6 mm.
  • the thickness of the rods 5 In the hardest sections of the saddle, i.e. , in the middle of the sitting parts 7 symmetrically on the left and right sides, the thickness of the rods 5 is 1.7 mm. In the softest sections of the saddle, i.e. , in the tip 9 and the rear part 10 , the thickness of the rods 5 is 1 mm.
  • Example 2 describes a bicycle handlebar grip with areas of different softness made of the material according to the present invention.
  • the material with locally variable softness and flexibility and structural characteristics according to Example 1 is adapted to the shape of a bicycle handlebar grip a 3D-printing method based on laser sintering of a powder layer in a powder bed of a thermoplastic polyurethane.
  • B-type cuboids 2 are located on the outside where the grip is held
  • A-type cuboids 1 are located on the inside where the grip rests on the handlebar tube, and the edges are equipped with a skirt made of a thin layer of TPU.
  • the grip has an overall length of 129 mm, its overall diameter at the widest part 16 is 46 mm, and its overall diameter at the narrowest part 17 is 34 mm.
  • the cells that make up the grip have a height ranging from 6 mm to 10 mm.
  • the thickness of the rods 5 In the hardest section of the grip, i.e. , in the narrowest part 17 , the thickness of the rods 5 is 1.7 mm. In the softest section of the grip, i.e. , in the widest part 16 , the thickness of the rods 5 is 1.3 mm. Between the hardest and softest sections of the grip is a transition part 18 , in which the thickness of the rods 5 continuously changes between values of 1.3 mm and 1.7 mm, thereby achieving a continuous change in the softness of the grip between the widest part 16 and the narrowest part 17 .
  • 3D printed material with a variably flexible internal structure is industrially applicable in the manufacturing of flexible materials with controlled stiffness, for example in the field of production of sports equipment.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)

Abstract

La présente invention concerne un matériau imprimé en 3D formé par des cellules (3) contenant des cuboïdes de type A et de type B (1, 2), des tiges (5) d'un cuboïde de type (1) s'étendant du centre (111) de la face de référence (11) au centre (121) de chaque bord vertical de référence (12), chaque tige (5) étant en contact avec les deux côtés de référence respectifs (13), des tiges (5) s'étendant du centre (141) de la face de référence (14) au centre (121) de chaque bord vertical de référence (12), chaque tige (5) en contact avec les deux faces de référence respectives (22) du bord donné (12) et des centres (121) des bords verticaux de référence (12) sont partagés par au moins deux cellules, dans le cuboïde de type B (2), des tiges (5) s'étendent du centre (211) de la face de référence (21) à chaque sommet (222) de la face de référence (22), chaque tige (5) en contact avec la face de référence (22) et les sommets (222) de la face de référence (22) sont partagés par au moins deux cellules, des tiges (5) sont raccordées au niveau du point de rencontre.
PCT/CZ2023/050078 2022-11-13 2023-11-10 Matériau imprimé en 3d doté d'une structure interne souple de manière variable, en particulier pour la production d'équipement de sport WO2024099488A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CZ2022-469A CZ309784B6 (cs) 2022-11-13 2022-11-13 3D tištěný materiál s variabilně flexibilní vnitřní strukturou, zejména pro výrobu sportovního vybavení
CZPV2022-469 2022-11-13

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WO2024099488A1 true WO2024099488A1 (fr) 2024-05-16

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WO2003011679A1 (fr) 2001-07-25 2003-02-13 Claus Oehler Procede pour l'adaptation individuelle de selles de vehicules a deux roues
US20070273185A1 (en) 2005-03-31 2007-11-29 Specialized Bicycle Components, Inc. Saddle fit system and method
WO2014209308A1 (fr) * 2013-06-26 2014-12-31 Hrl Laboratories, Llc Appareil structural à micro-treillis à écoulement d'air élevé
CN111251641A (zh) 2014-11-05 2020-06-09 耐克创新有限合伙公司 方法及柔性网格状泡沫
US20200281310A1 (en) 2015-05-08 2020-09-10 Under Armour, Inc. Footwear midsole with lattice structure formed between platforms
US20200046062A1 (en) 2016-10-20 2020-02-13 C & J Clark International Limited Articles of footwear
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CN208783842U (zh) 2018-06-04 2019-04-26 福建泉州匹克体育用品有限公司 一种鞋底内嵌3d打印模块的运动鞋
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CN110560837A (zh) * 2019-08-05 2019-12-13 华中科技大学 一种电弧熔丝增材制造金属点阵结构的方法及产品

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