Intelligent, additively-manufactured outerwear and methods of manufacturing thereof

• US 10,638,927 B1
• Filed: 05/15/2015
• Issued: 05/05/2020
• Est. Priority Date: 05/15/2014
• Status: Active Grant

• Current Assignee: Casca Designs Inc.
• Original Assignee: Casca Designs Inc.
• Inventors: Beard, Lucy A., Beard, Nigel P.
• Primary Examiner(s): Vo, Tu A
• Application Number:
  US14/714,024
• Time in Patent Office: 1,817 Days
• CPC Class Codes: A43B 3/30 specially adapted for babies or small children
• CPC Class Codes: A43B 3/34 with electrical or electronic arrangements
• CPC Class Codes: A43B 7/147 for sick or disabled persons, e.g. persons having osteoarthritis or diabetes
• CPC Class Codes: A61B 2562/12 Manufacturing methods specially adapted for producing sensors for in-vivo measurements
• CPC Class Codes: A61B 5/00 Measuring for diagnostic purposes radiation diagnosis A61B6/00; diagnosis by ultrasonic, sonic or infrasonic waves A61B8/00; Identification of persons
• CPC Class Codes: A61B 5/0022 Monitoring a patient using a global network, e.g. telephone networks, internet
• CPC Class Codes: A61B 5/02 Detecting, measuring or recording pulse, heart rate, blood pressure or blood flow; Combined pulse/heart-rate/blood pressure determination; Evaluating a cardiovascular condition not otherwise provided for, e.g. using combinations of techniques provided for in this group with electrocardiography or electroauscultation; Heart catheters for measuring blood pressure
• CPC Class Codes: A61B 5/02055 Simultaneously evaluating both cardiovascular condition and temperature
• CPC Class Codes: A61B 5/026 Measuring blood flow A61B3/1233, A61B3/1241 take precedence
• CPC Class Codes: A61B 5/03 Detecting, measuring or recording fluid pressure within the body other than blood pressure, e.g. cerebral pressure; Measuring pressure in body tissues or organs A61B5/205 takes precedence
• CPC Class Codes: A61B 5/1074 Foot measuring devices
• CPC Class Codes: A61B 5/1079 using optical or photographic means
• CPC Class Codes: A61B 5/1112 Global tracking of patients, e.g. by using GPS
• CPC Class Codes: A61B 5/1118 Determining activity level
• CPC Class Codes: A61B 5/112 Gait analysis
• CPC Class Codes: A61B 5/6807 Footwear
• CPC Class Codes: A61H 1/008 Apparatus for applying pressure or blows almost perpendicular to the body or limb axis, e.g. chiropractic devices for repositioning vertebrae, correcting deformation
• CPC Class Codes: A61H 2201/0103 inflatable
• CPC Class Codes: A61H 2201/0188 Illumination related features
• CPC Class Codes: A61H 2201/0207 heated
• CPC Class Codes: A61H 2201/10 : with further special therapeutic means, e.g. electrotherapy, magneto therapy or radiation therapy, chromo therapy, infrared or ultraviolet therapy
• CPC Class Codes: A61H 2201/1207 : with electric or magnetic drive
• CPC Class Codes: A61H 2201/1238 : with hydraulic or pneumatic drive
• CPC Class Codes: A61H 2201/1409 : Hydraulic or pneumatic means
• CPC Class Codes: A61H 2201/1642 : Holding means therefor
• CPC Class Codes: A61H 2201/1647 : the anatomy of a particular individual
• CPC Class Codes: A61H 2201/165 : Wearable interfaces
• CPC Class Codes: A61H 2201/1697 : Breathability of the material
• CPC Class Codes: A61H 2201/5007 : computer controlled
• CPC Class Codes: A61H 2201/5023 : Interfaces to the user
• CPC Class Codes: A61H 2201/5025 : Activation means
• CPC Class Codes: A61H 2201/5061 : Force sensors
• CPC Class Codes: A61H 2201/5071 : Pressure sensors
• CPC Class Codes: A61H 2201/5082 : Temperature sensors
• CPC Class Codes: A61H 2201/5097 : wireless
• CPC Class Codes: A61H 2203/0406 : Standing on the feet
• CPC Class Codes: A61H 2205/12 : Feet
• CPC Class Codes: A61H 2230/255 : used as a control parameter for the apparatus
• CPC Class Codes: A61H 2230/805 : used as a control parameter for the apparatus
• CPC Class Codes: A61H 23/00 : Percussion or vibration massage, e.g. using supersonic vibration; Suction-vibration massage; Massage with moving diaphragms apparatus for passive exercising A61H1/00; generating or transmitting mechanical vibrations in general B06B
• CPC Class Codes: A61H 23/0245 : with ultrasonic transducers, e.g. piezoelectric
• CPC Class Codes: A61H 39/04 : Devices for pressing such points, e.g. Shiatsu or AcupressureMassage or pressure on general areas A61H9/00 - A61H23/00
• CPC Class Codes: A61H 9/0078 : with intermittent or alternately inflated bladders or cuffs mattresses for preventing bed-sores with alternated pressurized chambers A61G7/05776
• CPC Class Codes: B29C 64/393 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 50/00 : Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing

Abstract

Described herein are customized, intelligent outerwear created through additive manufacturing and integrated with a plurality of sensors, actuators and other electronics to monitor user activity and provide various diagnostic and therapeutic capabilities. The outerwear is additively manufactured using a three-dimensional (“3D”) printer to provide for dynamic configurations of the sensors, actuators and other electronics depending on the specific needs of an individual. In addition to sensors for tracking motion, resistance, temperature and temporal features, the actuators may include piezoelectric components and microfluidic components to provide for therapeutic treatments, medical treatments and accident avoidance features. The combination of sensors and other electronics may also provide applications for monitoring overall health and growth.

Claims

1. A diagnostic and therapeutic outerwear system, the system comprising:

a processor configured to facilitate;

receiving one or more images of a portion of a body of a user;

creating a three-dimensional (3D) model of the portion of the body of the user based at least in part on the one or more images;

determining at least one material suitable for additive manufacturing of an outerwear configured to be worn on the portion of the body of the user; and

generating, using an additive manufacturing process, the outerwear made at least in part from the at least one material, wherein the outerwear is formed to provide a custom fit, based on the 3D model, to the portion of the body of the user where the outerwear is worn;

one or more sensors embedded within the outerwear, the one or more sensors configured to generate diagnostic output signals that convey information related to one or more of physical activity of the user or physiological information of the user, the diagnostic output signals communicated to one or more computing devices; and

one or more actuators embedded within the outerwear, the one or more actuators configured to provide therapy to the user, the actuators controlled by the one or more computing devices to provide the therapy based on the diagnostic output signals,

wherein, the processor is further configured to facilitate;

forming the one or more sensors and the one or more actuators integrally in the outerwear during additive manufacturing; and

forming interlocking tabs and holes in the outerwear during additive manufacturing for locking the one or more sensors and the one or more actuators to the outerwear such that the one or more sensors and the one or more actuators are embedded therein.

2. The system of claim 1, wherein at least one of the one or more actuators comprises a device selected from the group consisting of a heater, a sonication device, an electrode, an inflatable pocket, and a microfluidic channel that responds to pressure applied to the channel by the user.

3. The system of claim 2, wherein at least one of the one or more actuators is configured such that the therapy provided to the user is selected from the group consisting of electronic muscle stimulation, heat therapy provided to the portion of the body of the user, pressure massaging provided to the portion of the body of the user, and vibrational massaging provided to the portion of the body of the user.

4. The system of claim 1, wherein at least one of the one or more sensors is selected from the group consisting of a weight distribution sensor, a user gait sensor, a geolocation sensor, a temperature sensor, and a blood flow sensor.

5. The system of claim 1, wherein the one or more sensors include one or more of a piezoelectric material, or an electrically conductive graphene based material printed directly into the outerwear.

6. The system of claim 1, wherein the one or more sensors include a weight sensor and a gait sensor.

7. The system of claim 1, wherein the one or more actuators further comprise at least one microfluidic channel in the outerwear.

8. The system of claim 1, wherein the one or more sensors and the one or more actuators are embedded with the outerwear in one or more locations that are determined based on user information including information related to one or more of a physical activity level of the user, a disability of the user, an age of the user, biomechanical information about the user, or a physical history of the user.

9. The system of claim 1, wherein the outerwear is a shoe, and wherein a weight distribution of the user in the shoe is determined by the one or more computing devices based on the output signals.

10. The system of claim 1, wherein the one or more sensors are coupled with flexible batteries embedded in the outerwear configured for near-field charging without physical connection to an external power source;

and

wherein the one or more sensors are coupled with wireless network components and/or cell signal components embedded in the outerwear and configured to facilitate transfer of data from the one or more sensors to cloud storage and/or electronic applications.

11. The system of claim 1, wherein the outerwear is a selection of three-dimensional (3D) printed shoes that correct orthotic issues over time.

12. A method for forming diagnostic and therapeutic outerwear, the method comprising:

receiving one or more images of a portion of a body of a user;

creating a three-dimensional (3D) model of the portion of the body of the user based at least in part on the one or more images;

determining at least one material suitable for additive manufacturing of an outerwear configured to be worn on the portion of the body of the user;

generating, using an additive manufacturing process, the outerwear made at least in part from the at least one material, wherein the outerwear is formed to provide a custom fit, based on the 3D model, to the portion of the body of the user where the outerwear is worn;

generating, with one or more sensors embedded within the outerwear, diagnostic output signals that convey information related to one or more of physical activity of the user or physiological information of the user, the diagnostic output signals communicated to one or more computing devices;

providing, with one or more actuators embedded within the outerwear, therapy to the user, the actuators controlled by the one or more computing devices to provide the therapy based on the diagnostic output signals, and

forming the one or more sensors and the one or more actuators integrally in the outerwear during additive manufacturing and forming interlocking tabs and holes in the outerwear during additive manufacturing for locking the one or more sensors and the one or more actuators to the outerwear such that the one or more sensors and the one or more actuators are embedded therein.

13. The method of claim 12, wherein at least one of the one or more actuators comprises a device selected from the group consisting of a heater, a sonication device, an electrode, an inflatable pocket, and a microfluidic channel that responds to pressure applied to the channel by the user.

14. The method of claim 13, wherein the therapy provided to the user is selected from the group consisting of electronic muscle stimulation, heat therapy provided to the portion of the body of the user, pressure massaging provided to the portion of the body of the user, and vibrational massaging provided to the portion of the body of the user.

15. The method of claim 12, wherein at least one of the one or more sensors is selected from the group consisting of a weight distribution sensor, a user gait sensor, a geolocation sensor, a temperature sensor, and a blood flow sensor.

16. The method of claim 12, wherein the one or more sensors include one or more of a piezoelectric material, or an electrically conductive graphene based material printed directly into the outerwear.

17. The method of claim 12, further comprising generating the diagnostic output signals using at least a weight sensor and a gait sensor.

18. The method of claim 12, further comprising providing the therapy using at least one microfluidic channel in the outerwear.

19. The method of claim 12, further comprising embedding the one or more sensors and the one or more actuators with the outerwear in one or more locations that are determined based on user information including information related to one or more of a physical activity level of the user, a disability of the user, an age of the user, biomechanical information about the user, or a physical history of the user.

20. The method of claim 12, wherein the outerwear is a shoe, the method further comprising determining a weight distribution of the user in the shoe with the one or more computing devices based on the output signals.

21. The method of claim 12, wherein the one or more sensors are coupled with flexible batteries embedded in the outerwear configured for near-field charging without physical connection to an external power source;

and

wherein the one or more sensors are coupled with wireless network components and/or cell signal components embedded in the outerwear and configured to facilitate transfer of data from the one or more sensors to cloud storage and/or electronic applications.

22. The method of claim 12, wherein the outerwear is a selection of three-dimensional (3D) printed shoes that correct orthotic issues over time.