Patent ID: 12228188

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present technology may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of components configured to perform the specified functions and achieve the various results. For example, the present technology may employ an outer structure connected together with any number of connectors having various shapes, lengths, and connection points. In addition, the present technology may be formed using any suitable material.

Methods and apparatus for a 3D-printed spring according to various aspects of the present technology may be integrated in any suitable system and/or device, such as door hinges, pool safety fencing, tension sensors, alignment parts (e.g., automotive parts), compression springs, workout equipment (e.g., those for strengthening the wrist, forearm, and/or grip), artwork, kitchen accessory, audio equipment (e.g., for vibration dampening), robotics (e.g., a catapult), shoes (e.g., within the soles to provide shock absorption), cushions (e.g., bike seats, internal springs for mattresses, and/or seat cushions), or any other application where compressive, extension, or torsion force is desired. For example, and referring toFIG.7, the 3D-printed spring may be integrated into a clip (such as a hair clip) to provide tension on two interleaved, comb-shaped portions.

Referring toFIGS.1-6, an exemplary 3D-printed spring100may be arranged to provide compression, extension, or torsion force against an external force.

For example, in various embodiments, the 3D printed spring100may provide a compression force when a first external force CF1and/or a second external force CF2is applied to the first and last toroidal elements (e.g., the first toroidal element105(1) and the eighth toroidal element105(8)). The first external force CF1may be applied in a first direction that is perpendicular to the toroidal element105. The second external force CF2may be applied in a second direction, opposite the first direction, that is perpendicular to the toroidal element105. For example,FIG.3illustrates the toroidal elements105oriented in a vertical manner. In this case, the first external force CF1may be horizontal, and thus, perpendicular to the toroidal element105. Similarly, the second external force CF2may be horizontal, and thus, perpendicular to the toroidal element105. Alternatively, the 3D spring100may be reoriented, such that the toroidal elements105are oriented in a horizontal manner. In this case, the first and second external forces CF1, CF2would be applied in a vertical direction (up or down).

In various embodiments, the 3D printed spring100may provide an extension force when a third external force EF1and/or a fourth external force EF2is applied to the first and last toroidal elements (e.g., the first toroidal element105(1) and the eighth toroidal element105(8)). The third external force EF1may be applied in a first direction that is perpendicular to the toroidal element105. The fourth external force EF2may be applied in a second direction, opposite the first direction, that is perpendicular to the toroidal element105. For example,FIG.3illustrates the toroidal elements105oriented in a vertical manner. In this case, the third external force EF1may be horizontal, and thus, perpendicular to the toroidal element105. Similarly, the fourth external force EF2may be horizontal, and thus, perpendicular to the toroidal element105. Alternatively, the 3D spring100may be reoriented, such that the toroidal elements105are oriented in a horizontal manner. In this case, the first and second external forces CF1, CF2would be applied in a vertical direction (up or down).

In various embodiments, the 3D printed spring100may provide a torsion force when a fifth external force RF1and/or a sixth external force RF2is applied to at least two of the toroidal elements. For example, the fifth external force RF1may be applied to the first toroidal element105(1) and the sixth external force RF2may be applied to the eighth toroidal element105(8). Alternatively, the fifth external force RF1may be applied to the first and third toroidal elements105(1),105(3) and the sixth external force RF2may be applied to the sixth and eighth toroidal elements105(6),105(8). Alternatively, the fifth external force RF1may be applied to the first, third, fifth, and seventh toroidal element105(1),105(3),105(5),105(7) and the sixth external force RF2may be applied to the second, fourth, sixth, and eighth toroidal elements105(2),105(4),105(6),105(8). It will be understood that the fifth and sixth external forces RF1, RF2may be applied to any number or any combination of toroidal elements based on the particular application and/or the desired spring/torsion force. For example, in some applications, applying the fifth and sixth external forces RF1, RF2to four toroidal elements (e.g., the first and third toroidal elements105(1),105(3) and the sixth and eighth toroidal elements105(6),105(8)) will result in a torsion force greater than applying the fifth and sixth external forces RF1, RF2to only two toroidal elements (e.g., the first toroidal element105(1) and the eighth toroidal element105(8)). In other words, the greater the number of toroidal elements that are directly affected by the external force, the greater the effective torsion force.

The fifth external force RF1may be applied in a first direction that rotates the toroidal element105. The sixth external force RF2may be applied in a second direction that rotates the toroidal element105, wherein the second direction is opposite the first direction.

In various embodiments, the external forces (EF1, EF2, CF1, CF2RF1, RF2) may be applied to one or more locations on the 3D-printed spring100and may be applied in one or more directions. For example, the external force may be applied to one location on a toroidal element or multiple locations on a toroidal element. In addition, more than one external force may applied at the same time. For example, the torsion force may be applied at the same time as the compression force. The source of the external force may be from an element that is integrated or otherwise fused to the 3D-printed spring100(via the 3D printing process). Alternatively, the source of the external force may be from an element that is attached (by way of an adhesive, a fixture, or the like) to the 3D-printed spring100after the 3D-printed spring100has been formed.

In an exemplary embodiment, the 3D-printed spring100may comprise an outer structure comprising a plurality of toroidal elements105, such as toroidal elements105(1)˜105(8). The 3D-printed spring100may further comprise a plurality of connectors110, such as connectors110(1)˜110(7), connected to the outer structure.

In an exemplary embodiment, each toroidal element105may comprise an outer surface200defined as an outermost boundary of the outer structure. Each toroidal element105may further comprise an inner surface205, opposite to the outer surface200, and defined as an interior and innermost boundary of the toroidal element105. Each toroidal element105may further comprise a first side edge300defined as a surface of the toroidal element105that is perpendicular to both the outer surface200and the inner surface205. Each toroidal element105may further comprise a second side edge310opposite to the first side edge300and perpendicular to the both the outer surface200and the inner surface205. The toroidal elements105(1)˜105(8) may be arranged side-by-side, such that the outer surfaces200of each toroidal element105faces in a same direction and a first side edge300of one toroidal element105faces a second side edge310of a neighboring toroidal element105. For example, the first side edge300of a second toroidal element105(2) faces the second side edge310of a first toroidal element105(1).

In an exemplary embodiment, each toroidal element spaced apart from a neighboring toroidal element by a distance d. The distance d may be selected according to the particular application. For example, in the case of a compressive 3D-printed spring, the distance d may be larger than in the case of an extension 3D-printed spring to provide varying degrees of overall compression of the 3D-printed spring when compressed. Alternatively, in the case of an extension 3D-printed spring, the distance d may be smaller than in the compressive case to provide extension capabilities and minimal compressive capabilities. In some cases, the distance d may be selected to provide both compression and extension capabilities. In addition, the distance d may be limited by the particular 3D printer used to produce the 3D-printed spring100, as different 3D printers may have different minimum specifications at which they are able to print the 3D-printed spring100. For example, a particular 3D printer may require a distance d greater than 0.2 mm, while another 3D printer may require at distance d greater than 0.8 mm.

In various embodiments, the outer structure may comprise any number of toroidal elements105. The number of toroidal elements105may be selected based on the particular application and/or the desired amount of compression, extension, or torsion force. For example, the number of toroidal elements105may be increased or decreased to meet the desired overall length L of the 3D-printed spring100in a neutral state (i.e., without force applied to 3D-printed spring100).

In addition, the size of the toroidal elements105may vary according to the particular application. For example, larger toroidal elements105may be desired in applications where the expected force is greater while smaller toroidal elements105may be desired in application where the expected force is smaller. In some embodiments, all of the toroidal elements105(e.g., toroidal elements105(1)˜105(8)) may be the same size.

In some embodiments, some toroidal elements105may be larger in size than other toroidal elements105. For example, a first toroidal element (e.g., toroidal element105(1)) and a last toroidal element (e.g., toroidal element105(8)) may be larger in size and/or diameter than the middle toroidal elements (e.g., toroidal elements105(2)˜105(7)). In addition or alternatively, one or more middle toroidal elements may be larger in size than a neighboring toroidal element. For example, a fourth toroidal element105(4) may be larger in size than a third toroidal element105(3), and fifth toroidal element105(5) may be larger in size than a sixth toroidal element105(6). In various applications, the larger-sized toroidal elements may be used as an anchor or attachment point for a secondary component/element.

The shape of the toroidal elements105may vary according to the particular application. In various embodiments, the outer surface200of the toroidal elements105may form a circular shape (e.g., as illustrated inFIG.2), an oblong shape, a square shape, a diamond shape, a hexagonal shape (i.e., a toroidal polyhedral), and the like. In addition, the inner surface205may form the same shape as the outer surface200. For example, in the case of a toroidal element105having a circular revolution (FIG.4), a radius r is constant throughout. Alternatively, in the case of a toroidal element105having a square revolution (or rectangular revolution), a width W is constant.

Furthermore, the size and shape may be selected to fit into a particular three dimensional space. In other words, the maximum size and particular shape of the 3D-printed spring100may be limited to the maximum parameters of the three dimensional space that the 3D-printed spring will occupy.

In some cases, the overall size and dimensions of the 3D-printed spring100may be limited to the capacity of the build chamber for a particular 3D printer (not shown). For example, the 3D printer may have a build chamber having a 15 inch cube capacity. This means that the 3D printer has the ability to produce any 3D-printed spring having overall dimensions less than 15 inches by 15 inches by 15 inches.

In various embodiments, the 3D-printed spring100may have any number of connectors110. The total number of connectors110may be based on the total number of toroidal elements105. In an exemplary embodiment, the total number of connectors is one less than the total number of toroidal elements105. For example, if the 3D-printed spring has eight (8) toroidal elements105, then the 3D-printed spring100will have seven (7) connectors110.

In an exemplary embodiment, each connector110may comprise a first end210and an opposing second end215. The first end210may connect to the inner surface205of one toroidal element105while the second end215may connect to the inner surface205of a neighboring toroidal element105. For example, and referring toFIGS.2,4, and5, a first end210(1) of a first connector110(1) is connected to the inner surface205of the first toroidal element105(1) and a second end215(1) of the first connector110(1) is connected to the inner surface205of the second toroidal element105(2). Similarly, a first end210(2) of a second connector110(2) is connected to the inner surface205of the second toroidal element105(2) and a second end215(2) of the second connector110(2) is connected to the inner surface205of a third toroidal element105(3).

In various embodiments, the location of the connection points changes with every other connector, thus the overall position and direction of every other connector changes relative to an immediately proximate connector. For example, odd-numbered connectors, such as connectors110(1),110(3),110(5), and110(7), have a different overall position and direction from the even-numbered connectors, such as connectors110(2),110(4),110(6), and110(8).

In one embodiment, the odd-numbered connectors, such as connectors110(1),110(3),110(5), and110(7), may be arranged to have the same direction and position with respect to each other when the 3D-printed spring100is in the neutral state. This may be achieved by arranging the first ends of the odd-numbered connectors to have a same position, relative to a reference point220, on the respective toroidal element105and arranging the second ends of the odd-numbered connectors to have a same position, relative to the reference point, on the respective toroidal element105.

Similarly, even-numbered connectors, such as connectors110(2),110(4),110(6), and110(8), may be arranged to have the same direction and position with respect to each other when the 3D-printed spring is in the neutral state. This may be achieved by arranging the first ends of the even-numbered connectors to have a same position, relative to the reference point220, on the respective toroidal element105and arranging the second ends of the even-numbered connectors to have a same position, relative to the reference point220, on the respective toroidal element105.

In other embodiments, the even-numbered connectors may be offset from each other and the odd-numbered connectors may be offset from each other. In other words, the position of the first and second ends of the even-numbered connectors, relative to the reference point220, may vary from one even-numbered connector to another even-numbered connector, and the position of the first and second ends of the odd-numbered connectors, relative to the reference point220, may vary from one odd-numbered connector to another odd-numbered connector.

In various embodiments, and when viewed from the front (e.g., as illustrated inFIG.2), one connector and an immediately-adjacent connector may form a t-shape or an x-shape. The pattern may be described according to an angle θ formed between one connector, such as the first connector110(1), and an immediately adjacent connector, such as the second connector110(2). The degree of the angle θ is related to the position of one connector relative to an immediately-adjacent connector and may range from zero to ninety degrees.

In various embodiments, the connectors110may have any suitable size and shape. In one embodiment, the connectors110are shaped as a square prism (e.g., as illustrated inFIG.5). In other embodiments, the connectors110are shaped as a triangular prism, a hexagonal prism, a pentagonal prism, or any other suitable prism shape. In other embodiments, the connectors110are shaped as a cylinder. In addition, in an exemplary embodiment, the connectors110are linear. Alternatively, the connectors110may be curved (arched), have an S-shape, or any other suitable arrangement.

The size and shape of the connectors110may be based on the type of force and/or the amount of force and/or the amount of torque desired. For example, an overall circumference of each connector110may be varied to increase or decrease the force of the 3D-printed spring100. In various embodiments, the larger the overall circumference, the greater the amount of extension (tensile) and/or compression force. In addition, the larger the overall circumference, the greater the amount of torsion force required to twist the 3D-printed spring100.

In addition, a length L of each connector110may be varied to provide a particular type and/or amount of force. For example, longer connectors110may be used to provide compressive force, while shorter connectors110may be used to provide tensile force. In the case of a compressive 3D-printed spring, the longer the length L of the connectors110, the greater the compressive force. In the case of an extension 3D-printed spring, the shorter the length L of the connectors110, the greater the tensile force. In various embodiments, the length L of each connector110will dictate the distance d that separates one toroidal element105from a neighboring toroidal element105.

In an exemplary application, the 3D-printed spring100may be integrated into a clip700, such as a hair clip. In an exemplary embodiment, the clip700may comprise the 3D-printed spring100, a first member705, and a second member710. The first member705may comprise a first grip portion715and a first comb-shaped portion720. Similarly, the second member710may comprise a second grip portion725and a second comb-shaped portion730.

The first member705may be connected or otherwise fused (via the 3D printing process) to one or more points or locations of the 3D-printed spring100. Similarly, the second member710may be connected or otherwise fused (via the 3D printing process) to one or more points or locations of the 3D-printed spring100. For example, the first member705may be connected to a first toroidal element105(e.g., toroidal element105(1)) of the 3D-printed spring100and the second member710may be connected to a last toroidal element105(e.g., toroidal element105(8)) of the 3D-printed spring100. For example, the first member705may connect to the entire outer surface200of the first toroidal element105(1) or one or more points or locations on the outer surface200of the first toroidal element105(1). Similarly, the second member710may connect to the entire outer surface200of the last toroidal element105(8) or one or more points or locations on the outer surface200of the last toroidal element105(8).

The first comb-shaped portion720may comprise a first plurality of fingers and the second comb-shaped portion730may comprise a second plurality of fingers. The first plurality of fingers may interleave the second plurality of fingers when the clip700and 3D-printed spring100are in the neutral state (e.g., as illustrated inFIGS.7-10).

In the present application, and referring toFIGS.1and7-10, the 3D-printed spring100may function as a torsion spring, such that when the first and second grip portions715,725are squeezed together, the first member705applies a rotational force in a first direction R1to the first toroidal element105(1), while the second member710applies a rotational force in a second direction R2, opposite to the first direction, to the last toroidal element105(8). This rotational force causes the first and second comb-portions720,730to separate from each other.

In the present application, the clip700may be produced as a single, integrated object. In other words, the clip700may not be made up of multiple, discrete components.

Various embodiments of the present technology may be produced using a combination of computer-aided design (CAD) software (not shown), such as Fusion360, and a 3D printer (not shown), such as an HP Multi Jet Fusion5210or similar. The CAD software may be used to create a 3D model of the spring100. The 3D model may be represented as one or more files containing data, information, and/or instructions (i.e., CAD files) related to aspects of the 3D-printed spring100, such as overall size, dimensions, spacing between the toroidal elements105, and the size, shape and length of the connectors110. In addition, a secondary software (not shown) may be used to “slice” the 3D model into hundreds or thousands of layers based on a desired print orientation of the spring100. The secondary software may generate a code that indicates the number of layers, temperature, layer height, print speed, and the like. The 3D printer may be configured to receive and execute the CAD files and/or the code from the secondary software.

The files containing data and/or instructions may also relate to a print orientation of the 3D-printed spring100. For example, the print orientation may indicate that the 3D-printed spring100will be formed/printed in a first orientation (e.g., as illustrated inFIG.3, wherein the toroidal elements105are oriented vertically) or in a second orientation (e.g., with the toroidal elements105orientated horizontally). The 3D-printed spring100may be produced using any suitable 3D-printer in combination with any suitable, compatible CAD software.

The 3D printer may be configured to form or print the 3D-printed spring100. The 3D printer may form/print the 3D-printed spring100according to the CAD files and/or the secondary software code. For example, the 3D printer may expel a layer of a print material, such as a plastic material. For example, the print material may comprise a powder-based material (e.g., PA 11 (also known as Polyamide 11 or Nylon 11) and PA 12 (also known as Polyamide 12 or Nylon 12), thermoplastic polyurethane (TPU), nylon plastic infused with glass beads (i.e., PA glass beads), and the like. Next, the 3D printer may deposit a fusing agent to the print material to fuse the print material. The 3D printer may then apply an energy source, such as infrared light or heat lamps, to the fused material to fuse the layers to each other. The 3D printer repeats this process for each layer until all layers have been completed, and thus completing the formation of the 3D-printed spring100.

In various embodiments, the 3D-printed spring100may be printed as a single, continuous component. In addition, the 3D-printed spring100may be printed in any orientation and without the aid of support structures or other restraints. For example, the 3D-printed spring100may be printed such that the toroidal elements105have a horizontal orientation (e.g., a first print orientation). Alternatively, the 3D-printed spring100may be printed such that the toroidal elements105have a vertical orientation (e.g., a second print orientation).

In various embodiments, the 3D-printer may print the clip700using a plastic material, such a powder-based material (e.g., PA 11 (also known as Polyamide 11 or Nylon 11) and PA 12 (also known as Polyamide 12 or Nylon 12), thermoplastic polyurethane (TPU), nylon plastic infused with glass beads (i.e., PA glass beads), and the like. In addition, the powder-based material may contain coloring, such that the clip700may be printed in any desirable color.

For example, the 3D printer may be configured to receive and execute one or more files containing data and/or instructions related to aspects of the clip700, such as overall size and dimensions of the clip700, including the dimensions and specifications of the first and second comb-shaped portions720,730, the dimensions and specifications of the first and second grip portions715,725, and dimensions and specifications of the 3D-printed spring100integrated within the clip700, such as the overall dimensions of the 3D-printed spring100, the spacing between the toroidal elements105, and the size, shape and length of the connectors110.

The files containing data and/or instructions may also relate to a print orientation of the clip700. The clip700may be produced using any suitable 3D-printer in combination with any suitable, compatible CAD software.

In various embodiments, the clip700may be printed as a single, continuous component. In addition, the clip700may be printed in any orientation and without the aid of support structures or other restraints.

Various embodiments of the present technology may undergo various post processing treatments, such as abrasion blasting, dyeing, graphite blasting, tumbler/mass finishing, polishing, automotive painting, electroplating, vapor smoothing, sanding, chrome painting, and hydro-dipping.

In the foregoing description, the technology has been described with reference to specific exemplary embodiments. The particular implementations shown and described are illustrative of the technology and its best mode and are not intended to otherwise limit the scope of the present technology in any way. Indeed, for the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the method and system may not be described in detail. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and/or steps between the various elements. Many alternative or additional functional relationships or physical connections may be present in a practical system.

The technology has been described with reference to specific exemplary embodiments. Various modifications and changes, however, may be made without departing from the scope of the present technology. The description and figures are to be regarded in an illustrative manner, rather than a restrictive one and all such modifications are intended to be included within the scope of the present technology. Accordingly, the scope of the technology should be determined by the generic embodiments described and their legal equivalents rather than by merely the specific examples described above. For example, the steps recited in any method or process embodiment may be executed in any order, unless otherwise expressly specified, and are not limited to the explicit order presented in the specific examples. Additionally, the components and/or elements recited in any apparatus embodiment may be assembled or otherwise operationally configured in a variety of permutations to produce substantially the same result as the present technology and are accordingly not limited to the specific configuration recited in the specific examples.

Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments. Any benefit, advantage, solution to problems or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced, however, is not to be construed as a critical, required or essential feature or component.

The terms “comprises”, “comprising”, or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the present technology, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same.

The present technology has been described above with reference to an exemplary embodiment. However, changes and modifications may be made to the exemplary embodiment without departing from the scope of the present technology. These and other changes or modifications are intended to be included within the scope of the present technology, as expressed in the following claims.