Shape morphing behavior has applications in many fields, and the most common approach to achieve shape morphing structures is through shape memory alloys or hydrogels. These materials undergo differential strains which generate a variety of shapes. New shape morphing techniques are needed to address other needs in various industries and fields.
It is with these concepts in mind, among others, that various aspects of the present disclosure were conceived.
This Summary provides an introduction to some general concepts relating to this invention in a simplified form that are further described below in the Detailed Description.
Aspects of the disclosure relate to methods of manufacturing a three-dimensional structure, the steps including obtaining a first yarn material, the first yarn material having first material properties; obtaining a second yarn material, the second yarn material having second material properties; knitting the first yarn material and the second yarn material together to form a knit structure having a first shape; and applying a thermal load to at least one of the first yarn material or the second yarn material to thereby deform the first yarn material and/or the second yarn material and thereby form a second shape.
The first yarn material and the second yarn material can be knitted together using purl stitches. The first yarn material and the second yarn material can be knitted together using plain stitches. The first yarn material and the second yarn material can also be braided together.
The thermal load can cause the first yarn material to expand. Or the thermal load can cause the first yarn material to contract.
The first yarn material can be a natural material. The first yarn material comprises one of wool, cashmere, alpaca, cotton, linen, or bamboo. The first yarn material can be a synthetic material. The first yarn material comprises one of rayon, acrylic, nylon, or polymer. The first yarn material comprises twisted and coiled nylon fibers.
The method can also include applying a resin to the three-dimensional shape to thereby lock the knitted structure in the second shape. In other examples, the method can include removing the thermal load to thereby return the knitted structure to the first shape.
Aspects of this disclosure also relate to a knit structure including a first yarn material, the first yarn material having first material properties; a second yarn material, the second yarn material having second material properties; wherein the first yarn material and the second yarn material are knit together forming a first shape; and wherein when a thermal load is applied to at least one of the first yarn material or the second yarn material the first yarn material and/or the second yarn material deform thereby form a second shape. The first yarn material and the second yarn material can be knitted together using purl stitches. In other examples the first yarn material and the second yarn material can be knitted together using plain stitches. In examples, the first yarn material and the second yarn material can be braided together.
In some examples a resin is applied to the knit structure. In other examples, when the thermal load is removed the knit structure returns to the first shape. In some examples, the first yarn material includes a heating wire integrated with the first yarn material.
The foregoing and other objects, features, and advantages of the present disclosure set forth herein will be apparent from the following description of particular embodiments of those inventive concepts, as illustrated in the accompanying drawings. Also, in the drawings the like reference characters refer to the same parts throughout the different views. The drawings depict only typical embodiments of the present disclosure and, therefore, are not to be considered limiting in scope.
While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will herein be described in detail example embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the following description of various example structures according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example devices, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.
Also, while the terms “top,” “bottom,” “front,” “back,” “side,” “distal,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures or the orientation during typical use. Nothing in this specification should be construed as requiring a specific three-dimensional orientation of structures in order to fall within the scope of this invention. Also, the reader is advised that the attached drawings are not necessarily drawn to scale.
Aspects of the present disclosure relate to shape morphing. And in particular, aspects of this disclosure relate to the novel concept that two-dimensional knits comprised of yarns from different materials can be morphed into different three-dimensional shapes particularly when the yarns are under certain thermal loads. This novel concept can form a bridge between traditional knitting and shape changing structures. This novel concept is referred to herein Knitmorphing and/or Knitmorphs. As described herein knitted patterns of varying materials can morph into complex shapes, such as saddle, axisymmetric cup, and a plate with waves when subjected to thermal loads. Applications for Knitmorphs or Knitmorphing can include programmable knits for developing robots based upon jellyfish like locomotion, and complex structures similar to wind turbine blades. Additional examples and details related to structures and methods are described herein.
As described herein utilization of materials having different coefficients of thermal expansion can be important to Knitmorphing. Selected materials can include high values of thermal coefficient of expansion and contraction along with have low stiffness to facilitate morphing. The materials will expand or contract due to the coefficients of thermal expansion for the materials and these can be designed to for a particular shape. In some embodiments, twisted and coiled nylon polymers (TCP) fibers can be used in knitmorphing.
As described herein a method of manufacturing a three-dimensional structure through knit morphing can include the steps of: obtaining a first yarn material, the first yarn material having first material properties; obtaining a second yarn material the second yarn material having second material properties; and knitting the first yarn material and the second yarn material together to form a knit structure. A thermal load then may be applied to at least one of the first yarn material or the second yarn material to thereby deform the first yarn material and/or the second yarn material. This may cause the knit structure to form a three-dimensional shape. The materials discussed herein may deform according to a linear thermal expansion model:
where L is the length measurement of the material and dL/dT is the rate of change of that linear dimension per unit change in temperature.
In some examples the first yarn material and the second yarn material may be the same yarn material or may be different yarn materials. Additionally, the same thermal load may be applied to the entire knit structure or different thermal loads may be applied to different portions of the knit structure.
A knit structure may include: a first yarn material the first yarn material having first material properties; and a second yarn material the second yarn material having second material properties. The first yarn material and the second yarn material may be knit together. As described above, a thermal load can be applied to at least one of the first yarn material or the second yarn material the first yarn material and/or the second yarn material can deform such that the knit structure forms a three-dimensional shape. As described above, in some examples the first yarn material and the second yarn material may be the same yarn material or may be different yarn materials. Additionally, the same thermal load may be applied to the entire knit structure or different thermal loads may be applied to different portions of the knit structure.
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As shown and described in the examples above, a method of manufacturing three-dimensional structures using knitmorphing can include obtaining a first yarn material which can have certain material properties. Some of the material properties are shown in the charts above. The materials can have differing thermal coefficients and elastic moduli. The first yarn material 12 can be comprised of natural fibers including for example wool, cashmere, alpaca, cotton, linen, or bamboo. In other embodiments, the first yarn material 12 can be a synthetic material and can be comprised of fibers including rayon, acrylic, nylon, or polymer. As described above, in some embodiments, the first yarn material can comprise twisted and coiled nylon fibers. The method for manufacturing a three-dimensional structure using knit morphing can further include obtaining a second yarn material 14. The second yarn material 14 can be the same as the first yarn material 12 or different than the first yarn material 12 and may have the same material properties as the first yarn material 12 or different material properties than the first yarn material 12.
The method then includes knitting the first yarn material 12 and the second yarn material 14 together to form a knit structure having a first shape. The first yarn material and the second yarn material can be knit together using any known methods to form any desired shape. For example, and as shown above, the first and second yarn materials can be knit together using plain and/or purl stitches. In still other examples, the first yarn material and the second yarn material can be braided or coiled together rather than, or in addition to, being stitched together. Once the desired first shape has been attained, the method can continue by applying a thermal load to at least one of the first yarn material or the second yarn material. In some embodiments the thermal load can be thermal load can be from 293K to 696K. As shown and described above, the thermal load can cause the first yarn material and/or the second yarn material to deform. The deformation of the first yarn material and/or second yarn material can cause the first shape to deform and thereby form a second shape.
In some examples, after the thermal load has been applied to the knit structure, a hardening agent such as a resin may be applied to the knit structure to permanently harden the knit structure in the second shape. Such a method may be advantageous for production of large or difficult to transport shapes. For example, a knit structure can be knit at a first site and then transported to a second site where a thermal load and hardening agent can be applied. Such a manufacturing method can also be useful for manufacturing of large structures that require heavy logistical planning for transportation such as wind turbine blades, or to an industry requiring minimal storage consumption but rapid manufacturing, such as satellite or space exploration. In this dieless forming method, the knit structure can be pre-manufactured using a thermoplastic resin and packaged with ease of transportation or storage in mind.
In other examples the method for manufacturing a three-dimensional shape can further include removing the thermal load to thereby return the knitted structure to the first shape. Or in still other embodiments, the method for manufacturing a three-dimensional shape can further include applying a different thermal load than the first load to thereby form the knit structure into a different third shape. Such applications or removal of thermal loads can create a movable structure and may create a structure capable of locomotion. As shown for example in
As shown and described in the examples above, knitmorphing can produce a knit structure 10. The knit structure can include a first yarn material 12 which has first material properties and a second yarn material 14 which has second material properties. As disclosed above the material properties of the first and second yarn can be the same or different from each other. Further, as disclosed above the knit structure can be composed of any number of different or the same knit materials. As shown in
As described above, the knit structure may also include a hardening agent such as a resin which may permanently lock the knit structure in the second shape formation. Additionally, as described above, one or more of the yarn materials that make up the knit structure may include a heating element or heating wire which can be used to instigate the thermal load to the particular knit material.
Knitmorphing as described herein may be applicable to a number of different designs and industries because of its ability to form various complex shapes. For example, the shapes and products that may be formed through knitmorphing can include an oil pan bottom, car fenders, engine casings. In addition, development of prototypes can be accomplished bypassing the need to create complex molds. Morphing fabrics as described herein can be the cornerstone for dieless forming of composite suitable for personalized items and rapid prototyping. This reduction of initial investment in capital equipment and tooling with low cycle time could significantly reduce cost per unit stiffness to be at par with steels. Moreover, since the process can be fully automated, it makes it suitable for industrial applications. This would bring down the barriers obstructing the widespread adoption of composites in different manufacturing sectors such as the automotive industry.
The foregoing merely illustrates the principles of the disclosure. Various modifications and alterations to the described embodiments will be apparent to those skilled in the art in view of the teachings herein. It will thus be appreciated that those skilled in the art will be able to devise numerous systems, arrangements and methods which, although not explicitly shown or described herein, embody the principles of the disclosure and are thus within the spirit and scope of the present disclosure. From the above description and drawings, it will be understood by those of ordinary skill in the art that the particular embodiments shown and described are for purposes of illustrations only and are not intended to limit the scope of the present disclosure. References to details of particular embodiments are not intended to limit the scope of the disclosure.
This application claims the benefit of U.S. Provisional Application No. 63/331,437, filed Apr. 15, 2023, which is hereby incorporated by reference in its entirety
Number | Date | Country | |
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63331437 | Apr 2022 | US |