ELASTOMERIC COUPLING METHODS AND DEVICES
20260021420 ยท 2026-01-22
Inventors
- Kathryn Joan Yancey (San Clemente, CA, US)
- Brooke Dozier (Orlando, FL, US)
- Michael Kutcher (Toluca Lake, CA, US)
- Kenneth Chapman, JR. (South Pasadena, CA, US)
- Reona Toney (Northridge, CA, US)
- David Powell Goldberg (Altadena, CA, US)
- Whitney J. Babin (Windermere, FL, US)
- Christopher John Mazzella (Altadena, CA, US)
Cpc classification
International classification
Abstract
An animated device includes a skin. The skin includes a membrane formed of a first elastomeric material and a coupling feature coupled to the membrane. The coupling feature includes an elongated portion, and a second elastomeric material. The animated device includes a shell comprising a complementary elongated portion configured to couple to the elongated portion.
Claims
1. A skin for an animated device comprising: a membrane formed of a first elastomeric material; a coupling feature coupled to the membrane comprising: an elongated portion, and a second elastomeric material.
2. The skin of claim 1, wherein the first elastomeric material and the second elastomeric material are a same material.
3. The skin of claim 1, wherein the first elastomeric material and the second elastomeric material are a same class of material and the first elastomeric material has a first property different from a first property of the second elastomeric material.
4. The skin of claim 3, wherein the first property is a durometer.
5. The skin of claim 4, wherein the durometer of the second elastomeric material is greater than the durometer of the first elastomeric material.
6. The skin of claim 1, wherein the elongated portion comprises a protrusion extending from a surface of the membrane, the protrusion comprising a neck portion and a head portion.
7. The skin of claim 6, wherein the head portion comprises a lobe configured to couple to a complementary feature of a shell of the animated device.
8. The skin of claim 6, wherein the coupling feature is configured to enable the skin to move with respect to a shell of the animated device when the skin is coupled to the shell.
9. The skin of claim 8, wherein the movement comprises a rolling motion.
10. The skin of claim 1, wherein the elongated portion comprises an elongate channel formed in the membrane configured to receive a complementary elongated portion of a shell of the animated device.
11. The skin of claim 1, wherein at least one of the first elastomeric material or the second elastomeric material includes a magnetic property.
12. An animated device comprising: a skin comprising: a membrane formed of a first elastomeric material; a coupling feature coupled to the membrane comprising: an elongated portion, and a second elastomeric material; a shell comprising: a complementary elongated portion configured to couple to the elongated portion.
13. The animated device of claim 12, wherein the first elastomeric material and the second elastomeric material are a same class of material and the first elastomeric material has a first property different from a first property of the second elastomeric material.
14. The animated device of claim 13, wherein the first property is a durometer.
15. The animated device of claim 14, wherein the durometer of the first elastomeric material is greater than the durometer of the second elastomeric material.
16. The animated device of claim 12, wherein: the elongated portion comprises a protrusion extending from a surface of the membrane; the complementary elongated portion comprises a receptacle formed in the shell; and the protrusion is removably couplable to the receptacle.
17. The animated device of claim 12, wherein: the elongated portion comprises an elongate channel formed in the membrane; the complementary elongated portion comprises a protrusion formed disposed on, or integrally formed with, the shell; and the protrusion is removably couplable to the receptacle.
18. The animated device of claim 13, further comprising an actuator coupled to the shell and removably coupleable to the skin.
19. The animated device of claim 18, wherein the actuator includes the complementary elongated portion.
20. The animated device of claim 12, wherein the elongated portion further comprises a magnetic property and the complementary elongated portion comprises a magnetic element configured to attract the elongated portion through a magnetic force.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
DETAILED DESCRIPTION
[0035] The coupling features, systems, and related methods herein include providing a skin or other aesthetic covering or other surface and a shell (or other supporting substrate) for an animated device. As used herein, an animated device is meant to encompass any device that includes a substrate, one or more actuators, and can receive a skin. The type of animated device may be varied, e.g., a robot, a puppet, a costume, an animatronic device, or the like are all examples of animated devices. The skin generally includes a membrane with one or more coupling features to secure it to the shell. The skin generally fits over at least a portion, if not the entirety of the shell to conceal the shell and define a realistic appearance for the animated device. Often, the skin is made from a more flexible or softer material than the shell. The shell supports and defines a shape of the skin and is configured to actuate various portions, e.g., appendages, to introduce movement to the animated device. The shell includes or is coupled to actuators configured to impart motion to the animated device, which can move the shell, and along with it, portions of the skin.
[0036] Coupling features are cast or molded into the skin or shell typically using the same material or a material from the same class but with different properties, as the skin or shell (e.g., a base material). As used herein, a material class is any group of materials with similar chemical structures within a threshold. For example, a class of materials may include materials having the same type of monomer, but may be processed differently or have different functional or cross-linking groups, side chain lengths, main chain lengths, curing methods, catalysts, curing or vulcanizing agents, etc. to give members of the class different properties (e.g., color, durometer, elasticity, hardness, etc.) with respect to one another. A class of materials with a similar chemical structure may be formed of the same repeating chemical group including atoms of the same elements bonded with the same types of chemical bonds (e.g., covalent, ionic, metallic, double, etc.). In another example, a class of materials may use the same catalyst or have the same base parent chemical makeup. For example, a class of polyethylene materials may all have the same repeating ethylene (H.sub.2H.sub.4) monomer chemical group. In another example, a class of silicones may all have the same repeating siloxane (e.g., H[OSiH.sub.2]: OH or [OSiH.sub.2].sub.n) monomer chemical group. For example, a class of skin materials may include a silicone material, or two or more silicone materials having different properties such as durometer, elasticity, density, color, etc.
[0037] In some embodiments, the coupling features may be made from a same class of material as the base material, but with a different durometer. That is, the coupling feature may be harder or softer, or more or less dense than the base material, but may have similar properties. For example, the coupling features and the skin may be made from a same class of material (e.g., are both types of silicone), but with one or more different properties (typically hardness). The coupling features are configured to enable freeform and organic connections between the skin and the shell (or actuators), allowing more freedom for creative movement and more realistic skin movement. Further, the coupling features can be distributed across all topographies and areas of the skin, to distribute loads, increasing durability of the skin.
[0038] In one example, the coupling feature forms an integral protrusion from the shell. For example, the coupling feature may be cast or molded into the shell using a material having the same class as the class of the base material of the shell. The skin includes a complementary receptacle adapted to receive the protrusion. The protrusion may include features that lock the skin onto the shell, such as to prevent unwanted decoupling or relative movement and may be elongated, such as to impart motion (and coupling) to a large area.
[0039] In another example, the coupling feature is in the form of a flexible, substantially linear, or linear protrusion. For example, the protrusion may be cast or molded into the skin using a similar material as the base material of the skin. The shell includes a complementary receptacle adapted to receive the protrusion which may lock the shell onto the skin. The elongated length helps to increase the coupling force along a length and distribute loads.
[0040] Any coupling features disclosed may constrain relative motion between the skin and the shell to zero, one, two, three, or more degrees of freedom. For example, a flexible, linear coupling may allow some relative movement between the shell and the skin (e.g., may allow the skin to roll as the actuators move the shell). In another example, a coupling feature may lock the skin onto the shell to prevent or reduce unwanted movement.
[0041] In some embodiments, a coupling feature of either the skin or the shell may be conformally or correspondingly shaped, such as to mimic a shape of a biological feature. For example, a coupling feature may be shaped like a muscle, tendon, ligament, bone or other biological structure.
[0042]
[0043] The shell 104 serves as a rigid or semi-rigid structure to provide a base or support for the other components of the animated device 102. The shell 104 often defines the shape of the skin, e.g., as a volumetric shape. In the example shown and described with respect to
[0044] The skin 106 is configured to be positioned over at least a portion of the shell 104 and conceal portions thereof. The skin 106 is typically formed from one or more types of flexible materials, such as elastomeric or rubber materials. In many embodiments, the skin materials mimic the appearance and properties of biological skin or other surfaces, depending on the creature or object being replicated by the animated device 102. In some embodiments, the skin may be formed of one or more of silicone, natural or artificial rubber, polymer (e.g., polyurethane or latex) foam, thermoplastic or thermoset elastomers, polyvinyl chloride, etc. Any of the skin materials may have different hardness (typically measured as durometer). In many examples, skin materials of the same class may have different properties such as durometer. Several actuators such as an actuator 108a, an actuator 108b, an actuator 108c are coupled to the shell and removably coupled to the skin. In other examples, more or fewer actuators may be used. The actuators cause the skin or other portions of the animated device 102 to move to perform an animation. For example, the animated device 102 includes eyes 110 that may be moveable by one or more of the actuators 108a-c. Actuators may be pneumatic, hydraulic, electric, piezoelectric, electroactive polymer, or shape memory devices, etc. As can be appreciated the shape, positioning, and movement of the movable portions may be varied based on the character features, e.g., if the character is meant to represent a human it may include movable legs and arms and if the character is meant to represent a bird it may include movable wings and a beak.
[0045] The shell 104 may include one or more coupling features adapted to couple (including removably couple) the skin 106 to the shell 104. In many cases, the skin 106 is removably attachable to the shell 104, such as to facilitate replacement of the skin 106 as desired, for example to replace a worn or damaged skin, change skin properties, or even change the character represented by the animated device 102. A coupling feature enables the skin 106 (or other versions of a skin) to be repeatedly and reliably coupled to the shell 104 in many cases.
[0046] Coupling features may be in many forms, depending on the desired coupling strength, movement relative to the shell, as well as degrees of movement expected for the shell portion onto which the skin will be attached. For example as shown in
[0047] As shown for example in
[0048] Turning to
[0049] Turning to
[0050] A benefit of the coupling of the skin 106 and the shell 104 may be that the skin 106 is easy to locate on the shell 104 to achieve quick changes of skin with repeatable animation results. Prior methods require skilled technicians to accurately locate a new skin 106 on a shell 104 to avoid drooping or sagging features that can ruin an animation effect. Here, the coupling features enable easy and repeatable coupling of a skin 106 and shell 104 without specialize skills or tools.
[0051] In some embodiments, the channel coupling feature 300 may be elongated, as well as be continuous or discontinuous (e.g., as shown for example in
[0052] The example channel coupling feature 300 shown in
[0053] In some embodiments, the channel coupling feature 300 can be used to control rotation or other movement of the skin 106 with respect to the shell 104. For example, the lobe 304 may prevent or limit relative rotation of the skin 106 with respect to the shell 104. In other embodiments, the head portion 310 may include rounded or other features that enable some rotation of the skin 106 with respect to the shell 104.
[0054] The channel coupling feature 300 may be made of the same material as the shell 104 or a different material. In some embodiments, the shell 104 is made of the same class of material as the channel coupling feature 300 but with one or more different properties. For example, the shell 104 may be made of a relatively hard (e.g., high durometer) polymer (such as polyethylene) while the channel coupling feature 300 may be made of a softer or more compliant polyethylene material. In some embodiments, the channel coupling feature 300 may include layers or portions of different materials to achieve more accurate or lifelike motions of the animated device 102.
[0055] Turning to
[0056] In some embodiments, the receptacle 410 has a complementary shape to the protrusion 406 such that the protrusion 406 may be received in the receptacle 410. For example, the protrusion 406 may snap or click into the receptacle 410. In some embodiments, the receptacle 410 includes a clearance portion 408 with a dimension greater than a corresponding portion of the protrusion 406 (shown for example in
[0057] The flexible linear coupling feature 400 may be made of the same material as the skin 106 or a different material. In some embodiments, the skin 106 is made of the same class of material as the flexible linear coupling feature 400 but with one or more different properties. For example, the skin 106 may be made of a relatively soft (e.g., low durometer) polymer (such as silicone) while the flexible linear coupling feature 400 may be made of a stiffer or harder silicone material. In some embodiments, the flexible linear coupling feature 400 may include layers or portions of different materials to achieve more accurate or lifelike motions of the animated device 102.
[0058] Turning to
[0059] The conformal coupling feature 500 may include a locator 502 that helps position the conformal coupling feature 500 with respect to the skin 106 and/or the shell 104. The locator 502 may include a protrusion 504 that rises or extends from an inner surface of the conformal coupling feature 500. In some embodiments, the protrusion 504 may be a magnetic coupling feature 506 configured to be attracted to a corresponding magnetic feature on the shell 104 or the skin 106.
[0060] The conformal coupling feature 500 may be made of the same material as the skin 106 or a different material. In some embodiments, the skin 106 is made of the same class of material as the conformal coupling feature 500 but with one or more different properties. For example, the skin 106 may be made of a relatively soft (e.g., low durometer) polymer (such as silicone) while the conformal coupling feature 500 may be made of a stiffer or harder silicone material. In some embodiments, the conformal coupling feature 500 may include layers or portions of different materials to achieve more accurate or lifelike motions of the animated device 102.
[0061]
[0062] According to some examples, the method 700 includes providing a shell 104 based on an animated device design at operation 702. For example, a user may generate a design for a character or model for the animated device 102. The model may include a computer-generated solid model of the character. A shell is created based on the model. For example, where the character is a human, the shell may be substantially similar to a human skull. Where the character is a fictional or fantasy character, the shell may be shaped to provide a structure to the animated device 102 and to provide support for the actuators that execute the animation of the 102.
[0063] According to some examples, the method 700 includes providing a skin based on the shell at operation 704. The skin design may be based on layers of simulated or actual soft tissue that the animated device 102 is meant to emulate. For example, where the animated device 102 is a human character, the skin may include layers of elastomers that emulate the properties, motion, and/or structure of the layers of human soft tissue, such as tendons, ligaments, fat, muscle, skin, and/or hair. The skin may be cast or molded from a skin material such as silicone or another elastomer. For example, a mold may be created representing a negative structure of the skin and/or shell. The mold may be filled with a skin material and the material allowed to harden or cure. The skin may be removed from the mold subsequent to the curing process. In some embodiments, the skin may be removed from the mold before the curing process is complete (e.g., the elastomer is still slightly soft and under-cured).
[0064] According to some examples, the method 700 includes coupling one or more coupling features into the skin or shell at operation 706. The coupling features may be any coupling feature disclosed herein. In many examples, the coupling features are molded or cast into the skin 106 or shell 104. The coupling features may be made of the same or similar materials or same class of materials as the skin. In some embodiments, the coupling features may be cast or molded into the skin while the skin is under-cured. A benefit of this embodiment of the operation 760 may be that, the coupling feature chemically integrates with the base material of the skin. For example, when a fresh, uncured elastomeric material of a coupling feature is cast or molded into the under-cured base material of the skin, and the materials of the skin and the coupling feature are of the same class of material, the coupling feature material may chemically bond with the under-cured skin material and vice-versa as both materials cure. Thus, a strong, bond between the skin and coupling feature may be formed. Furthermore, the properties of the mixing region where the skin and coupling feature materials intermingle may have a gradient of properties from the skin to the coupling feature (e.g., durometer) thereby reducing stress and improving the lifelike appearance and reliability of the resulting animated device. The method 700 improves over prior methods of providing skins to animated features. For example, by first casting the skin as in the operation 704, and then casting or molding the coupling features into the skin, better adhesion between the skin and the coupling features may be achieved. With better adhesion, the coupling features and skin may provide for more lifelike or accurate motion for the animated device 102, increased reliability due to the reduction or elimination of stress risers, and/or improvement in the case of replacing a skin 106 on an animated device 102.
[0065] According to some examples, the method 700 includes coupling the skin 106 to the shell 104 at operation 708. For example, a protrusion 306 of a channel coupling feature 300 may be coupled (including removably coupled) to a channel 302 as described with respect to the channel coupling feature 300. In another example, a flexible linear coupling feature 400 may be coupled to a receptacle 410 as discussed with respect to the flexible linear coupling feature 400. In another example, where a coupling feature includes a magnetic property, the coupling feature may be placed in proximity to corresponding or complementary magnetic elements 118 disposed in the shell 104. When placed in proximity, the coupling features with a magnetic property may be attracted to, or repulsed by, the magnetic elements 118. When attracted, the magnetic attraction may help to couple the skin to the shell. Where repulsed, the magnetic repulsion may be used to achieve a desired motion effect of the skin.
[0066] According to some examples, the method 700 includes coupling the skin to one or more actuators at operation 710. In some examples, the operation 710 is optional. An actuator may include any coupling feature disclosed herein. For example, an actuator may include a channel coupling feature 300 coupleable to a channel 302 formed in the skin 106. In another example, the actuator may include a receptacle 410 configured to receive a flexible linear coupling feature 400. In another example, a post on the shell 104 and/or an actuator may be received in a receptacle of any of the coupling features disclosed herein.
[0067] The description of certain embodiments included herein is merely exemplary in nature and is in no way intended to limit the scope of the disclosure or its applications or uses. In the included detailed description of embodiments of the present systems and methods, reference is made to the accompanying drawings which form a part hereof, and which are shown by way of illustration specific to embodiments in which the described systems and methods may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice presently disclosed systems and methods, and it is to be understood that other embodiments may be utilized, and that structural and logical changes may be made without departing from the spirit and scope of the disclosure. Moreover, for the purpose of clarity, detailed descriptions of certain features will not be discussed when they would be apparent to those with skill in the art so as not to obscure the description of embodiments of the disclosure. The included detailed description is therefore not to be taken in a limiting sense, and the scope of the disclosure is defined only by the appended claims.
[0068] From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention.
[0069] The particulars shown herein are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present disclosure and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of various embodiments of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for the fundamental understanding of the invention, the description taken with the drawings and/or examples making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
[0070] As used herein and unless otherwise indicated, the terms a and an are taken to mean one, at least one or one or more. Unless otherwise required by context, singular terms used herein shall include pluralities and plural terms shall include the singular.
[0071] Unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of including, but not limited to. Words using the singular or plural number also include the plural and singular number, respectively. Additionally, the words herein, above, and below and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of the application.
[0072] All relative, directional, and ordinal references (including top, bottom, side, front, rear, first, second, third, and so forth) are given by way of example to aid the reader's understanding of the examples described herein. They should not be read to be requirements or limitations, particularly as to the position, orientation, or use unless specifically set forth in the claims. Connection references (e.g., attached, coupled, connected, joined, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other, unless specifically set forth in the claims.
[0073] Of course, it is to be appreciated that any one of the examples, embodiments or processes described herein may be combined with one or more other examples, embodiments and/or processes or be separated and/or performed amongst separate devices or device portions in accordance with the present systems, devices and methods.
[0074] Finally, the above discussion is intended to be merely illustrative of the present system and should not be construed as limiting the appended claims to any particular embodiment or group of embodiments. Thus, while the present system has been described in particular detail with reference to exemplary embodiments, it should also be appreciated that numerous modifications and alternative embodiments may be devised by those having ordinary skill in the art without departing from the broader and intended spirit and scope of the present system as set forth in the claims that follow. Accordingly, the specification and drawings are to be regarded in an illustrative manner and are not intended to limit the scope of the appended claims.