Soft robotic actuators and methods of manufacturing the same

• US 10,173,328 B2
• Filed: 03/23/2016
• Issued: 01/08/2019
• Est. Priority Date: 03/23/2015
• Status: Active Grant

• Current Assignee: Soft Robotics Inc.
• Original Assignee: Soft Robotics Inc.
• Inventors: Lessing, Joshua Aaron, Knopf, Ryan Richard, Vause, Carl Everett, Harburg, Daniel Vincent
• Primary Examiner(s): Vu, Stephen A
• Application Number:
  US15/078,966
• Publication Number:
  US 20160279803A1
• Time in Patent Office: 1,021 Days
• Field of Search: 294208, 2941193
• CPC Class Codes: B25J 15/0023 Gripper surfaces directly activated by a fluid flexible fingers B25J15/12
• CPC Class Codes: B25J 9/142 comprising inflatable bodies
• CPC Class Codes: B29C 2793/0009 Cutting out
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/3474 perpendicular to the plane of the joint
• CPC Class Codes: B29C 66/433 Casing-in, i.e. enclosing an element between two sheets by an outlined seam for bookbinding B42C11/06; for packaging B65B; by laminating B32B37/00; enclosing tubular articles between substantially flat elements B29C66/53261
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/712 the composition of one of the parts to be joined being different from the composition of the other part
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/729 Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/91221 of the parts to be joined
• CPC Class Codes: B29C 66/91231 of the joining tool
• CPC Class Codes: B29K 2021/00 Use of unspecified rubbers as moulding material
• CPC Class Codes: B29K 2021/003 : Thermoplastic elastomers
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B32B 2037/268 : Release layers
• CPC Class Codes: B32B 2262/0215 : Thermoplastic elastomer fibers
• CPC Class Codes: B32B 2262/0253 : Polyolefin fibres
• CPC Class Codes: B32B 2262/0261 : Polyamide fibres
• CPC Class Codes: B32B 2262/0269 : Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2266/0207 : Materials belonging to B32B25/00
• CPC Class Codes: B32B 2274/00 : Thermoplastic elastomer material
• CPC Class Codes: B32B 2305/022 : Foam
• CPC Class Codes: B32B 2305/34 : Inserts
• CPC Class Codes: B32B 2307/306 : Resistant to heat
• CPC Class Codes: B32B 2309/02 : Temperature
• CPC Class Codes: B32B 2319/00 : Synthetic rubber
• CPC Class Codes: B32B 2367/00 : Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2375/00 : Polyureas; Polyurethanes
• CPC Class Codes: B32B 2377/00 : Polyamides
• CPC Class Codes: B32B 2457/00 : Electrical equipment
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/10 : characterised by a discontinuous layer, i.e. formed of separate pieces of material
• CPC Class Codes: B32B 3/16 : secured to a flexible backing
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 33/00 : Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 37/10 : characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/182 : one or more of the layers being plastic
• CPC Class Codes: B32B 38/0004 : Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/10 : Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: F15B 15/103 : using inflatable bodies that contract when fluid pressure is applied, e.g. pneumatic artificial muscles or McKibben-type actuators
• CPC Class Codes: F15B 2215/305 : characterised by the use of special materials

Abstract

Exemplary embodiments relate to various improvements in soft robotic actuators, and techniques for manufacturing the improvements. For example, techniques for manufacturing a rigidizing layer for reinforcing a soft robotic actuator is provided. In another embodiment, a soft robotic actuator having integrated sensors is described. A flexible electroadhesive pad for achieving a conformal grip is also described. Still further, exemplary embodiments provide hydraulically-actuated soft robotic grippers, which allows for a reduction in the size of the actuation system and improved underwater operation.

Claims

1. A rigidizing layer for a soft robotic actuator, the rigidizing layer formed by:

disposing a fabric sheet on a bottom plate of a hot press;

disposing a layer of thermoplastic material on the fabric sheet, the layer of thermoplastic material having a plurality of slots formed in it;

disposing a rigid slat in each of the slots in the layer of thermoplastic material;

disposing a compliant supportive layer on the layer of thermoplastic material and the slats;

disposing a top plate of the hot press on the compliant supportive layer;

operating the hot press to bond the fabric sheet, the layer of thermoplastic material, and the compliant supportive layer together to form a bonded sheet; and

cutting the rigidizing layer from the bonded sheet.

2. The rigidizing layer of claim 1, wherein the fabric sheet comprises nylon.

3. The rigidizing layer of claim 1, wherein the thermoplastic material comprises thermoplastic polyurethane (TPU).

4. The rigidizing layer of claim 1, further comprising disposing a gasket on the compliant supportive layer, the gasket having a number and arrangement of slots formed in corresponding to a number and configuration of the slots formed in the layer of thermoplastic material.

5. The rigidizing layer of claim 1, wherein the compliant supportive layer comprises a stretching foam.

6. The rigidizing layer of claim 1, wherein the compliant supportive layer comprises spandex and neoprene foam.

7. A soft robotic actuator assembly comprising:

a soft robotic actuator comprising a plurality of accordion extensions extending outwards in a radial direction;

a camshaft connected to a first end of a follower;

a piston, connected to a second end of the follower, wherein the follower and the camshaft drive the piston, for supplying hydraulic fluid to a tube connected to the soft actuator to pressurize the soft actuator; and

an oblong lobe connected to the camshaft, wherein a pressure profile delivered by the piston is a function of a shape of the oblong lobe.

8. The assembly of claim 7, further comprising a set of hydraulically-actuated soft actuators that are driven out of phase from one another by the action of a single piston chamber.

9. The assembly of claim 7, wherein the piston is controlled by a linear actuator.