Patent Application
20190062155
This invention is directed to a microstructured surface having an engineered surface exhibiting touch aesthetics as a physical property of the surface.
Human each day experience a wide variety of touch aesthetics that occur in nature. This may be the skin of an infant, the fur of a pet, the roughness of tree bark, the prickle of a cocklebur or sunflower stalk, or the slick hardness of a polished stone. In contrast manmade surfaces, particularly on molded goods, tend to feel artificial like plastic.
Certain touch sensations can result in a pleasurable effect on humans such as “velvet soft”. Other touch sensations can result in discomfort and even pain such as “prickly”. Product designers have for many decades spent much effort to design molded products that have improved appearance. Techniques like chemical etching, engraving and more recently laser engraving of mold surfaces to make rubber and plastic articles provide a wide range of appearances including leather, tree bark, basket weave, diamond, and a variety of polishes. However, even though the appearance varies widely, the touch aesthetic still feel unpleasant and artificial. Product designers desire to augment visual aesthetics with touch aesthetics so that molded rubber and plastic goods can feel are variety of ways such as skin-like, fur-like, or tree bark-like to better serve a wide range of consumer tastes and needs. To enable the design process for touch aesthetics, new tools are needed.
There is a need for a common written nomenclature describing a range of touch sensations. There is also a need for an algorithm connecting the nomenclature to design parameters for a micro surface. Using the design parameters and knowledge of the desired material, a micro surface can then be designed to deliver a wide range of touch sensations such as found in nature. This ability would offer many advantages over current surface treatments and designs. For example, a customer might desire that their phone case feels like a particular flower petal.
Certain sensations can also provide utility such as haptic feedback as disclosed in United States Patent Application Publication 2013/0207793 which discloses electroactive transducers as well as methods of producing a haptic effect in a user interface device simultaneously with a sound generated by a separately generated audio signal and electroactive polymer transducers for sensory feedback applications in user interface devices as disclosed. Additionally, there has been research suggesting that touch is truly fundamental to human communication, bonding, and health. On the other hand, certain tactile sensations serve as warning and assist to prevent harm to humans, such as the pain felt when we contact sharp objects.
Each of these tactical sensations are designed to improve user experiences with such items as consumer products, tools, apparel and other items that generally have manmade surfaces. For example, the touch pad of a portable computer as shown in U.S. Pat. No. 7,119,291.
With our increased understanding of the effect of touch and tactile feel of surfaces on humans, there is a growing desire to provide proper tactile sensation experiences with consumer products as well as other surfaces in which we frequently interact. For example, U.S. Pat. No. 5,834,668 discloses a keyboard apparatus having keys that are relatively light in weight and low in cost and yet provide a “good key touch feeling”.
Such efforts to provide touch sensations can effect purchasing decisions (including desirability of consumer goods), emotional feeling, and mental attitude, according to one study. In this study, a Johns Hopkins neuroscientist concluded that due to the complex and counterintuitive system of human touch, our scientific understanding of touch, especially how it is processed in the brain, is much more limited when compared to our knowledge of other senses. However, we know that there are two distinct and parallel pathways to the brain for processing touch: a sensory pathway that includes facts about touch such as vibration, pressure, location and fine texture and one for processing social, and emotional information concerning the emotional content of different sensors of the skin (e.g. pleasure and pain centers of the brain).
As more and more synthetic materials comprise our environments, the less opportunities there are for surfaces to include touch sensations directed to our ability to process and be effected be touch. One attempt to provide a synthetic surface that purports to provide an interactive platform for the simulation of auditory and haptic experiences of everyday materials in walking is reported in a recent article. See Yon Visell, et al., An Architectural Platform for Audio-Haptic Simulation in Walking, Proc. Of the 4th Intl. Conf. on Enactive Interfaces (ENACTIVE 2007), Grenoble, France, (2007). However, these methods seek to use technologies for generating virtual experiences of material with the intrinsically tangible, physical, and spatial experience. These attempts to provide touch sensation with manmade materials have not focused on the material surfaces themselves. It would be desirable to have an engineered surface where the touch sensation properties of the surface can be designed and manufactured with a degree of confidence that the touch sensation will be fairly consistent across individuals.
With the exception of crystals, flat smooth surfaces are fairly rare in nature. However, flat or polished surfaces are quite common in manmade articles such as glass, composites, plastics, sanded wood, etc. It would be advantageous to provide a manmade surface that retained the physical properties such as strength, durability and ease of manufacturer while also having improved touch aesthetics provided to the individual. Such applications are wide ranging from tools, sporting equipment, accessories including jewelry, consumer products such as touch screen and computer touch pads, and others. One attempt to provide for improved touch sensation includes United States Patent Application Publication 20080305305 that discloses a skin material having a uniform thickness and improved touch such as moist (supple) feel and smoothness without deterioration in material appearance for automotive interior applications. This material is described as a substrate having a polymeric layer with a first surface adhering to the substrate and a second surface exposed to the outside and formed with a pattern of fine recesses wherein the fine recesses have a depth of 30 to 130 μm and a projected area ratio of 5 to 20% with respect to the total projected area of the second surface of the polymeric layer. However, this reference is very limited to a specific touch aesthetic in a narrow range of surface structure and cannot provide an engineered surface with multiple touch aesthetics.
Further attempts to provide surfaces with specific touch sensations include coatings such as with Teflon, sandpaper, and adhesives, for example, the HTC Hero, released around 2009, is a cell phone with a Teflon coated case. Further, such attempts such as sandpaper do not have reproducible or consistent surface configurations as the deposition of material (sand) on the substrate (paper) is generally in a random pattern. Further, coating and adhesives cannot be applied to a wide range of materials such as rubber, plastic, polymers, or metals. Use of coatings and other additives have their disadvantages and it would be advantageous to have an engineered surface that provides predictable and reproducible touch aesthetic without relying on coatings.
An object of the present invention is to provide a touch map so that a consumer product such as a phone case can be designed by locating the touch sensation of a desired object (e.g. flower petal) and designing the product with this characteristic.
It is another object to provide for a system or method that allows a designer to use the touch map to find the micro surface design parameters required to create a man-made surface that feels like the desired surface.
It is an object to provide a system or method for a designer to select the grip and appearance aesthetics that are appropriate for the tastes of the customer desiring the product development and design.
It is an object to provide a system and method for how the touch aesthetics, the grip aesthetics and the appearance aesthetics can be varied over a wide range to give improved products.
The objects above are achieved by providing a method for providing a microstructured surface comprising the steps of selecting a material having a desired hardness for a given application; selecting a microstructure pattern having an arrangement of microfeatures to provide at least one desired touch aesthetic to be applied to said material, wherein the width and aspect ratio of the microstructures are configured to provide said desired touch aesthetic for the hardness of the material selected; selecting said microstructure pattern to further include at least one desired physical property independent of said touch aesthetic to be applied to said material, wherein at least one of a pitch and spacing of said microfeatures is configures to provide said desired physical property selected from the group consisting of friction coefficient and grip force; determining the dimensions of said microstructure pattern to be applied to the surface of said material according to said desired physical properties, desired touch aesthetics and material hardness; and, engineering the material with said microstructure pattern by forming a negative of the microstructure pattern and providing an end product in the selected material from the negative having the microstructure patterned with the desired physical and aesthetic properties.
In a further advantageous embodiment, said material has between about 30 Shore A to 95 Shore A hardness.
In a further advantageous embodiment, said microfeatures range from between about 10 μm to about 500 μm.
In a further advantageous embodiment, said aspect ratio is from about 0.1 to 5.0 as calculated by
for a given microfeature.
In a further advantageous embodiment, said physical property of said microstructure pattern provides a grip force of at least about 35N to at least one of skin and fabric.
In a further advantageous embodiment, said touch aesthetic is selected from the group consisting of prickly, firm grip and comfortable, mink/cashmere, velvet, soft slick, firm rough painless, and soft rough, and combinations thereof.
In a further advantageous embodiment, said microstructure pattern having touch aesthetics of prickly or firm grip comfortable has microfeatures with a cross section width in the range of 20 μm to 200 μm, a spacing ratio calculated by
from 1.0 to 4.0, and an aspect ratio in the range of 1 to 5.
In a further advantageous embodiment, said microstructure pattern having touch aesthetics of prickly or firm grip comfortable has microfeatures with a sidewall draft angle from 0° to about 45°, corner radii in a range from 0% to about 50%.
In a further advantageous embodiment, a given microfeatures cross section has a shape selected from the group consisting of circle, rectangular, square, triangular, oval, polygonal, and line.
In a further advantageous embodiment, said microfeatures comprise at least one of recesses and pillars on the surface of said material.
In a further advantageous embodiment, said microfeatures comprise at least one of unstacked and stacked arrangements.
In a further advantageous embodiment, said microstructure pattern having touch aesthetics of mink/cashmere has microfeatures with a cross section diameter in the range of 20 μm to 100 μm, spacing ratio in the range of 0.7 to 4.0, and an aspect ratio in the range of 1.0 to 5.0.
In a further advantageous embodiment, said microstructure pattern having touch aesthetics of mink/cashmere has microfeatures with a sidewall draft from 0° to 10°, corner radii in the range of 0% to 50%.
In a further advantageous embodiment, said microstructure pattern having a touch aesthetic of Velvet has microfeatures with a cross section diameter in the range of 70 μm and 300 μm, spacing ration in the range of 1.0 to 4.0, and an aspect ratio in the range of 1.0 to 5.0.
In a further advantageous embodiment, said microstructure pattern having a touch aesthetic of Velvet has microfeatures with a sidewall draft in the range of 0° to 10°.
In a further advantageous embodiment, said microstructure pattern having a touch aesthetic of soft slick has microfeatures with an aspect ratio in the range of 0.1 to 2.0, spacing ratio in the range of 0.29 to 3.0, and a cross section diameter in the range of 20 μm to 70 μm.
In a further advantageous embodiment, said microstructure pattern having a touch aesthetic of soft rough on a material having a 60 Shore A value or less includes microfeatures with an aspect ratio in the range of 0.1 to 2.0, spacing ratio in the range of 1.0 to 2.5, and a cross section diameter in the range of 80 μm to 400 μm.
In a further advantageous embodiment, said microstructure pattern having a touch aesthetic of firm rough on a material having a Shore A value greater than about 60 includes microfeatures with an aspect ratio in the range of 0.1 to 2.0, spacing ratio in the range of 1.0 to 2.5, and a cross section diameter in the range of 80 μm to 400 μm.
The objectives are further achieved by a method for providing a microstructured surface comprising the steps of providing a touch map having an arrangement of microstructure patterns located across the surface of said map that define zones with unique touch aesthetics, wherein each zone is correlated with specific width and aspect ratios of microfeatures and a specific material hardness that combine to provide a given said touch aesthetic to each of said zones; selecting at least one desired touch aesthetic from said zones on said touch map; selecting a material having a hardness correlated with at least one of the selected said zones of said touch map for providing a selected said touch aesthetic to said material; selecting a microstructure pattern having an arrangement of microfeatures corresponding to the specific width and aspect ratios of microfeatures providing the touch aesthetic of the selected said zone for applying to said material; applying the dimensions of said microstructure pattern to a surface of said material to provide said material with said at least one touch aesthetic selected from said zones on said touch map.
In a further advantageous embodiment, a transition zone is included of about 20 μm or less to provide differing touch aesthetics between zones of said touch map.
The description of the invention will be explained with reference to the following figures:
It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of a preferred embodiment and not restrictive of the invention or other alternate embodiments of the invention. In particular, while the invention is described herein with reference to a number of specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention. Various modifications and applications may occur to those who are skilled in the art, without departing from the spirit and the scope of the invention, as described by the appended claims. Likewise, other objects, features, benefits and advantages of the present invention will be apparent from this summary and certain embodiments described below, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above in conjunction with the accompanying examples, data, figures and all reasonable inferences to be drawn therefrom, alone or with consideration of the references incorporated herein.
In general, the terms and phrases used herein have their art-recognized meaning, which can be found by reference to standard texts, journal references and contexts known to those skilled in the art.
Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise.
Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.
This invention provides a microstructured surface and method of manufacturing such surfaces to provide predictable and consistent touch aesthetics, especially with features in the 20 μm to 300 μm range. The touch aesthetics can be engineered and controlled using manufacturing processes such as those found in U.S. Pat. No. 8,720,047, incorporated by reference in its entirety. Referring to the following Table 1, physical properties for manmade materials having microstructures with microstructured patterns have corresponding physical properties and aspect ratios from 0.1 to 5.0:
The aspect ratio can be calculated by
By engineering and manufacturing the microstructured patterns with the various surfaces and physical properties, the surfaces created can include touch aesthetics taken from the group consisting of Prickly (prickle), Firm Grip and Comfortable; Mink/Cashmere, and Velvet. Touch aesthetics can be engineered by a combination of certain materials with specific hardness physical properties, microstructured patterns, and cross section widths for the microfeatures of the microstructure. The touch aesthetics, based upon engineering variation in these physical properties can transition from one touch aesthetics to another. Commonly these products are made by molding rubber or plastics. The invention also applies to other manufacturing methods including roll-to-toll processing, laser engraving, stamping, machining, or casting; and can be extended to other materials including metals and ceramics.
The sensation of touch occurs in the micron size range from about 10 microns to about 500 microns. Below this size range, surfaces feel uniformly smooth and may be slick, sticky, or have stick slip behavior depending on the material. Above this range, our skin and fingers perceive individual features and the surfaces on those features rather than the surfaces themselves. Parameters included in this invention are material hardness, microfeature width, and microfeature aspect ratio (height relative to width). An additional parameter, feature pitch (center to center distance) or spacing (pitch minus width) can be used to adjust friction coefficient and grip. The microfeatures that deliver touch and grip aesthetics, can conformally cover larger appearance features. The microfeatures can be visible to the naked eye or invisible.
Referring to
Referring to the following Table 2, physical properties for manmade materials having microfeatures with microstructured patterns have corresponding physical properties and aspect ratios from 0.1 to 2.0:
Referring to
In one embodiment, the material is made with various hard and soft materials, including polypropylene (60 shore D), 17-4PH stainless steel, 1010 carbon steel, 50 shore A silicone, 40 shore A silicone, 60 shore A TPU (thermoplastic polyurethane), 80 shore A TPU, 93 shore A TPU and 60 shore D TPU.
The touch aesthetics resulting from the engineered microstructured surfaces can be prickly and can be characterized as having individual microfeatures that have sufficient space between these features so that they can be resolved by rubbing against skin or scratching with fingernail. These microfeatures will not buckle when pressure is applied that is in excess of the pressure exerted on a surface by the average human hand. The microfeatures do not have a sufficient size to feel painful to the human when touched. A firm grip can be characterized by the increase in lateral sliding force relative to a non-micro structured surface. Comfortable can be characterized as not causing pain when touched or gripped, even when high force or high grip force is applied by a human hand.
To accomplish a touch aesthetic of Prickly, Firm Grip, Comfortable, one embodiment includes microstructures that have a microfeature cross section width in the range of 20 μm to 200 μm, a spacing ration calculated by
from 1.0 to 4.0. In one embodiment, the spacing ratio can be about 10 for certain materials that can include steel and brass. The aspect ratio can be in the range of 1 (having a width of 200 μm or less) and 5 (having a width of 50 μm or less). The microfeature can include a sidewall draft angle from 0° to about 45°.
For dry surfaces for each of the touch zones on
1 to 5
1 to 5
1 to 5
1 to 5
2 to 5
1 to 2
1 to 5
Referring to
For the touch aesthetic Mink/Cashmere, the microfeatures are too small a diameter for humans to individually resolve the microfeatures by touching. Surfaces with this touch aesthetic tend to feel warm to the touch as a result of trapped insulating air between the microfeatures. The materials used to provide this touch aesthetic include those with Shore A hardness of 75 A or lower. The microfeature cross section diameter can be in the range of 20 μm to 100 μm. The spacing ratio can be in the range of 0.7 to 4.0. The aspect ratio can be in the range of 1.0 to 5.0. The sidewall draft can be from 0° to 10°. The corner radii can be in the range of 0% to 50%. Patterns than can be included in this touch aesthetic include H001AP, H001BP (with a 100 μm height), H023AP, H012AP with some shown in
Touch aesthetic Velvet can be compared to the feeling of a tufted fabric. The microfeatures are large enough to individually resolve by human touching. The surface can feel warm as a result of trapped insulating air between the microfeatures. The materials used to provide this touch aesthetic include those with Shore A hardness of 75 A or lower. The microfeature cross section diameter can be in the range of 70 μm and 300 μm. The spacing ration can be in the range of 1.0 to 4.0. The aspect ratio can be in the range of 1.0 to 5.0. The sidewall draft can be in the range of 0° to 10°. Patterns that can be cooperative associated with this touch aesthetic include H021AP, H021BP, H190AP, H191AP including those shown in
Touch aesthetic Soft Slick can be characterized by a feel with a reduced friction surface. The human cannot distinguish individual microfeatures. The surface feels continuous. Patterns that can be cooperative associated with this touch aesthetic include H086BH, H401AP (only L2), H064AP, H025AP, H034AP, H002AP, H003DP, H379AP, H049AP, H012CP. Touch aesthetic Firm Rough can be characterized where the human can begin to distinguish individual microfeatures. The surface is painless even with pressure and the surface provides for a firm grip when grip or touch force is applied. Patterns that can be cooperative associated with this touch aesthetic include H160CP, H190AP, H021BP, H404AP (only L2), H008AH. Touch aesthetic Soft Rough can be characterized as having a slight fuzzy to stubble feeling surface. This surface can feel soft but the human can begin to perceive texture on the surface. A surface can include one or more of the three touch aesthetics described above and can have the following physical properties.
The microstructure associated with the touch aesthetic soft slick surface on any material can have an aspect ratio in the range of 0.1 to 2.0, spacing ratio in the range of 0.29 to 3.0, and microstructure cross section diameter in the range of 20 μm to 70 μm.
The touch aesthetic achieved as soft rough surface on a soft material having a 60 Shore A value or less can have an aspect ratio in the range of 0.1 to 2.0, spacing ratio in the range of 1.0 to 2.5, and microfeature cross section diameter in the range of 80 μm to 400 μm.
The touch aesthetic achieved as firm rough surface on a hard material having a Shore A value greater than 60 can include an aspect ratio in the range of 0.1 to 2.0, spacing ratio in the range of 1.0 to 2.5, and microfeature cross section diameter in the range of 80 μm to 400 μm.
The microfeatures can include a cross-sectional shape that can be, but not limited to circle, rectangular, square, triangular, oval, polygonal, and line. The microfeatures can be holes (recesses) or pillars and unstacked or stacked on one another.
In one embodiment, the engineered surface can be used for a trackpad (touch pads) that is commonly used for portable computers. Since the trackpad is from a manmade surface having touch aesthetics that are more than polished, smooth surfaces are desirable, especially when the surface should not be sticky. When manufactured, trackpads or touch pads are typically made from material with high Shore A values such as glass composites. Therefore, obtaining touch aesthetics that feel good, such as mink cashmere, velvet, soft rough and soft slick are difficult if not impossible to achieve. By using a microstructured surface of the present invention, these touch aesthetics can be imparted to the trackpads or touch pads without having to rely solely on material with high Shore A values.
In one embodiment, the engineered surface can be used for covers for electronic devices including phones and portable computers. Since electronic devices benefit from protective covers, it is beneficial to have such covers have sufficient soft material to adsorbe impact force while also having desirable touch aesthetics. Therefore, obtaining touch aesthetics that feel good, such as mink cashmere, velvet, soft rough and soft slick are desirable with material having mid to low Shore A values. By using a microstructured surface of the present invention, these touch aesthetics can be imparted to covers without reducing protective properties or feel.
Accordingly, those skilled in the art will recognize that the present invention can be applied to any number of materials used on a wide range of products, including but not limited to gripping surfaces on hand and power tools, sports equipment, medical devices, toys, and clothing, just to name a few.
While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.
| Number | Date | Country | |
|---|---|---|---|
| 62551492 | Aug 2017 | US |
