Printed Flexible Wristband

The present application is a nonprovisional application of and claims priority to U.S. Provisional Patent Application No. 63/523,948 filed on Jun. 29, 2023, and entitled “Printed Flexible Wristband,” which is incorporated herein by reference in its entirety.

The present disclosure is generally related to rubber and plastic wristbands, and more particularly, flexible wristbands printed using a three-dimensional printing process.

In recent years, silicon wristbands, sometimes referred to as rubber bracelets or gel bracelets, were made popular as a way of showing support for people fighting cancer. Lance Armstrong, the famous cyclist from Austin, Texas, popularized such wristbands by wearing a bright yellow silicon wristband with the word “LIVESTRONG” printed on it to signal support for people battling cancer.

Such silicon bracelets have been made in a variety of colors, allowing the wearers to show support for various causes. Business owners, fundraisers, and event promoters have adopted such silicon wristbands to promote their brands, to raise money, or even as event passes for festivals, concerts, and sporting events.

Silicon wristbands are produced by cutting a silicon rubber base into strips or tubes, placing the material into a steel mold to be melted and formed into a tube that can be cut into bands. Custom colors for the wristbands are mixed into the melted material before the molding process. In some instances, a second layer of ink may be applied to the wristband after the molding process is complete.

Debossed wristbands may include a logo or saying engraved into the silicon. Deboss-printed wristbands may include a logo or saying engraved into the silicon and then ink in a contrasting color may be applied into the engraved design to make the design stand out. In contrast, embossed wristbands may include a logo or design that is raised above a flat surface of the band, and the raised design or logo may be a different color from the rest of the band. Some silicon wristbands may be imprinted by applying ink to the flat surface of the silicon band.

In some implementations, such wristbands may be formed from two layers, an inner layer and an outer layer, which may be sonic welded or otherwise glued together. The inner layer and the outer layer may have different colors. In some implementations, such a wristband may be formed with a molded area in a center portion of the band where a design may be placed to enhance visibility.

Embodiments of devices and methods are described below in which a flexible wristband may be formed by a three-dimensional (3D) printing process. In some implementations, the 3D printing process may use digital light projection, oxygen-permeable optics, and engineering-grade materials to produce polymeric parts with exceptional mechanical properties, resolutions, and surface finishes. The 3D printing process may be used to produce integrated components or devices having geometries that cannot be produced by conventional molding techniques. Moreover, the 3D printing process may enable variations in the printed product based on software adjustments.

In some implementations, a wristband may be formed from an elastomeric polymer. The wristband may include a first edge, a second edge, and a lattice webbing extending between the first edge and the second edge. The first and second lattices may be separated by an air gap. The lattice webbing may be formed from a pattern of selected shapes, which may be a regular pattern or an irregular pattern. The lattice webbing may be formed from the same shape or different shapes, shapes of the same or different sizes, shapes of different thicknesses, or any combination thereof. The surface of the lattice webbing may be smooth or uneven, depending on the implementation. Further, the elastomeric polymer may include anti-microbial properties, anti-bacterial properties, wicking properties, or any combination thereof.

In some implementations, the wristband may include one or more edgesdefining a perimeter of the wristband. The wristband may include a first lattice webbing extending between first portions of the one or more edges and may include a second lattice webbing extending between second portions of the one or more edges and separated from the first lattice webbing by an air gap. One the one or more edges, the first lattice webbing, and the second lattice webbing are formed from additive layers without seams.

In other implementations, a wristband may include one or more edges defining a perimeter of the wristband and may include a first lattice webbing and one or more second lattice webbing. The first lattice webbing may include a first shape and may extend between first portions of the one or more edges. The one or more second lattice webbings may extend between second portions of the one or more edges and may be separated from the first lattice webbing by an air gap. The one or more second lattice webbings may include one or more of the first shape or a second shape. The one or more edges, the first lattice webbing, and the one or more second lattice webbings are formed from one or more elastomeric polymers constructed from additive layers without seams.

In still other implementations, a wristband may include one or more edges defining a perimeter of the wristband and may include a first lattice webbing and a second lattice webbing. The first lattice webbing may include a first pattern comprised of at least one first shape and may extend between first portions of the one or more edges. The second lattice webbing may extend between second portions of the one or more edges and may be separated from the first lattice webbing by an air gap. The second lattice webbing may include a second pattern comprised of at least one second shape. Each shape may be formed from a plurality of elements, at least some of which may have a spatially variable thickness. The one or more edges, the first lattice webbing, and the second lattice webbing may be formed from one or more elastomeric polymers constructed from additive layers without seams.

While implementations are described in this disclosure by way of example, those skilled in the art will recognize that the implementations are not limited to the examples or figures described. The figures and detailed description thereto are not intended to limit implementations to the form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope as defined by the appended claims. The headings used in this disclosure are for organizational purposes only and are not meant to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (in other words, the term “may” is intended to mean “having the potential to”) instead of in a mandatory sense (as in “must”). Similarly, the terms “include”, “including”, and “includes” mean “including, but not limited to”.

Embodiments of systems, methods, and devices are described below that may include a flexible wristband formed from an elastomeric polymer using a 3D printing process. The elastomeric polymer may exhibit a shore A hardness in a range from approximately 65 to 77 and a tear strength of 20 kilo-Newtons per meter or more. Additionally, the 3D printing process may enable printing of a lattice webbing of printed shapes that may have spatially varying dimensions, including sizes, depths, and thicknesses. In some implementations, strands or elements within the lattice webbing may have a thickness of approximately 0.6 mm, which may be too thin for manufacturing using injection mold or other plastic molding techniques with this type of elastic material.

In some implementations, the 3D printing process may use digital light projection, oxygen-permeable optics, and engineering-grade materials to produce polymeric parts with exceptional mechanical properties, resolutions, and surface finishes. The 3D printing process may be used to produce integrated components or devices having geometries that cannot be produced by conventional molding techniques. Moreover, the 3D printing process may enable variations in the printed product based on software adjustments.

In some implementations, a wristband may be formed from an elastomeric polymer may include a first edge, a second edge, and a lattice webbing extending between the first edge and the second and edge. The first and second lattices may be separated by an air gap. The lattice webbing may be formed from a pattern of selected shapes, which may be a regular pattern or an irregular pattern. The lattice webbing may be formed from the same shape or different shapes, shapes of the same or different sizes, shapes of different thicknesses, or any combination thereof. The surface of the lattice webbing may be smooth or uneven, depending on the implementation. Further, the elastomeric polymer may include anti-microbial properties, anti-bacterial properties, wicking properties, or any combination thereof. In some implementations, the elastomeric polymer may exhibit a short A hardness in a range from approximately 65 to 77 and a tear strength of 20 kilo-Newtons per meter or more. In some implementations, the lattice webbing may be formed from a plurality of elastomeric polymer elements having a spatially variable thickness. In some implementations, one or more of the elastomeric polymer elements may have a thickness of approximately 0.6 mm.

In some implementations, one or more pillars or tendrils may extend between the first and second lattices. The pillars or tendrils may be straight or curved and may include spatially variable thicknesses and shapes. For example, a pillar may be thicker in one portion than in other portions. In one possible implementation, a pillar may be thicker at a center portion than on its ends, or vice versa. Additionally, one or more of the pillars may curved while others may be straight. The straight pillars may extend perpendicular to or at another angle between the first and second lattices.

In general, the wristband may include a lattice webbing that may be formed by printing sequential layers. This process may enable lattice dimensions, thicknesses, spacing, interconnections (or absence of interconnections), or any combination thereof that may be difficult (if not impossible) to produce using a mold. The 3D printing process may enable selected or random variations in the lattice dimensions, patterns, and so on from wristband to wristband. An example of a flexible wristband produced by a 3D printing process is described below with respect to.

depicts a top view of a wristbandformed using a 3D printing process and including one or more edges, a lattice webbing, and an opening to provide a loop (elliptical loop) for an end of the wristband, in accordance with certain embodiments. The wristbandmay be formed from an elastomeric polymer material, which may be homogenous throughout the entire extent of the wristbandor which may vary, depending on the implementation. In some implementations, one or more parameters of the elastomeric material may vary across the wristband. The one or more parameters may include the color, the thickness, the composition, or any combination thereof. In some implementations, the thickness of lattice elements within the lattice webbingmay be tapered or may otherwise vary along their length. In an example, the lattice webbingmay include elements that have a spatially variable thickness. In some implementations, one or more of the elastomeric polymer elements may have a thickness of approximately.mm. In some implementations, the lattice webbingmay be formed in a single layer or may extend through one or more layers.

In the illustrated example, the wristbandmay include a plurality of adjustment holesdistributed along a first portion of the lattice webbingnear a first end of the wristband. The wristbandmay include a postnear a second end of the wristbandand extending at an angle of approximately ninety degrees from a surface defined by the lattice webbing.

The wristbandmay have an elongate, rectangular shape with rounded ends. The wristbandmay include one or more edgesthat define a perimeter of the wristband. In the illustrated example, the edgeis a continuous edge having rounded corners and defining a substantially rectangular wristbandwith rounded ends. In other implementations, the wristbandmay have an edgewith square corners defining a rectangle having four sides. The one or more edgesmay have a thickness that extends the full depth of the wristband. The one or more edgesextending about the perimeter of the wristbandmay define an area within the perimeter of the edgeor edges.

The lattice webbingmay be formed from one or more layers of material extending between the one or more edgesacross at least a portion of the area defined by the perimeter edges. In some implementations, the lattice webbingmay be formed from a first lattice webbing() and a second lattice webbing(), which may be separated by an air gap. In the illustrated example, the lattice webbingmay be formed by a plurality of honeycomb-shapes arranged in a substantially repeating pattern across the area and along at least portion of the length. In other implementations, the lattice webbingmay be formed by one or more shapes in a regular, semi-regular, or random configuration. In still other implementations, the lattice webbingmay be customized to include at least one lattice webbinghaving a custom configuration.

In some implementations, the lattice webbing() and the lattice webbing() may be formed from elastomeric polymer having a shore A hardness in a range from approximately 65 to 77 and a tear strength of 20 kilo-Newtons per meter or more. Additionally, the 3D printing process may enable printing of a lattice webbingof printed shapes that may have spatially varying dimensions, including sizes, depths, and thicknesses. In some implementations, strands or elements within the lattice webbingmay have a thickness of approximately 0.6 mm, which may be too thin for manufacturing using injection molding or other plastic molding techniques with this type of elastic material.

In some implementations, the additive layering of the 3D printing process may produce layer lines, which are sometimes referred to as “Z-lines”. Such lines are not present in devices produced by injection molding. Z-lines are sometimes visible (particularly under magnification) along the sides and edges of a printed part. However, machine processing or ink printing can blur such lines. In some implementations, the Z-lines may be visible through x-ray scanning, microscopic inspection, and the like.

depicts a side viewof the wristbandof. In this view, the postis shown to extend above the surface of the edgeof the wristband. Similarly, adjustment holes or openingsmay include a portion that may extend slightly past the surface of the edge. The holes or openingsmay be formed in the lattice webbingand may extend through one or more layers of the lattice webbing.

depicts a cross-sectional viewof the wristbandtaken along line C-C in, in accordance with certain embodiments. In this example, the wristbandmay include an edge. In this view, a first portion of the edge(first edge()) and a second portion of the edge(second edge()) are coupled by a first lattice webbing() and a second lattice webbing(), which are separated by an air gap.

In this example, the openingmay be formed from a first opening() in the first lattice webbing() and a second opening() in the second lattice webbing(). In this example, the airgapis maintained in the area of the openings.

In the illustrated example of, the lattice webbing() has a substantially constant thickness from the first edge() to the second edge(). Similarly, the lattice webbing() has a substantially constant thickness from the first edge() to the second edge(). In other implementations, one or more of the lattice webbing() or the lattice webbing() may have a spatially variable thickness, which may be produced by individual elements of the lattice.

In some implementations, the angular orientation of selected shapes within the lattice webbingmay vary, producing variability in the thickness of the lattice webbing. In other implementations, in addition to variability of the angular orientation, the shapes that comprise the lattice webbingmay vary. The thicknesses of the shapes, the sizes of the shapes, and their relative spacing may vary within a lattice webbing, between lattice webbings() and(), from wristbandto wristband, or any combination thereof.

depicts a cross-sectional viewof an alternative implementation of the wristbandtaken along line C-C in, in accordance with certain embodiments. In this example, the wristbandmay include all the elements of the wristbandin, except that the adjustment holeextends from the first lattice webbing() through the second lattice webbing(). In this example, the adjustment holemay form a hole postthat may extend between and through the lattice webbings() and(). The hole postmay surround the adjustment holeand may provide reinforcing force to secure the postin the adjustment hole. Other implementations are also possible.

depicts a top viewof a wristbandformed using a 3D printing process and including one or more edges, a lattice webbing, and a pair of loopsfor an end of the wristband, in accordance with certain embodiments. In this example, the wristbandincludes all the elements of the wristbandin, except that the elliptical loopis omitted, and replaced with a pair of loops.

In this example, the loopsmay extend away from a first edge(), extend over the lattice webbingby a predetermined spacing, and return to the second edge() to form a loopthrough which an end of the wristbandmay be inserted. The loopsare shown as solid structures, but the loopsmay be formed with edges and a secondary lattice formed from selected shapes, depending on the implementation.

depicts a side viewof the wristbandof. In this view, the loopsmay be formed as part of the edgesand printed to be coextensive with the edges. In some implementations, the wristbandmay be tapered slightly along its length so that an end of the wristbandmay fit through the loop.

depicts a perspective viewof a wristbandformed using a 3D printing process and including a lattice webbingwith embossed letteringand a solid area, in accordance with certain embodiments. In this example, the wristbandmay include all the elements of the wristbandin. In some implementations, the wristbandmay include edges() and(). The wristbandincludes one or more lattice webbings() and(). In some implementations, a portion of the wristbandmay be formed with an embossed logo(in this example, the word “FROGS”). Other logos may be embossed on the lattice webbing().

The wristbandmay also include a solid area, which may be formed to have a smooth surface to receive ink or into which letters may be formed. During the printing process, letters may be formed in this solid areaby withholding material to form the selected shape. In this example, the solid areamay include lettering. In some implementations, in addition to withholding some material during the printing process, a last layer prior to withholding material in the area of the letters may be printed with a different color of elastomeric polymer, causing the letters to be seen more easily against the background color of the wristband.

In this example, the wristbandis depicted as fan gear for the Texas Christian University (TCU), which are variously referred to as the “FROGS” or “HORNED FROGS”. It should be appreciated that the 3D printing process may enable other embossed logosor lettering. Additionally, while the examples provided above largely used hexagon-shaped structures to form the lattice webbing, other shapes may also be used.

depicts a top view of a wristbandformed using a 3D printing process and including one or more edges, a lattice webbing, and an opening to provide a loop (elliptical loop) for an end of the wristband, in accordance with certain embodiments. The wristbandmay be formed from an elastomeric polymer material, which may be homogenous throughout the entire extent of the wristbandor which may vary, depending on the implementation. In some implementations, one or more parameters of the elastomeric material may vary across the wristband. The one or more parameters may include the color, the thickness, the composition, or any combination thereof. In some implementations, the thickness of lattice elements within the lattice webbingmay be tapered or may otherwise vary along their length. In an example, the lattice webbingmay include elements that have a spatially variable thickness. In some implementations, one or more of the elastomeric polymer elements may have a thickness of approximately 0.6 mm. In some implementations, the lattice webbingmay be formed in a single layer or may extend through one or more layers.

In the illustrated example, the wristbandmay include a plurality of adjustment holesdistributed along a first portion of the lattice webbingnear a first end of the wristband. The wristbandmay include a postnear a second end of the wristbandand extending at an angle of approximately ninety degrees from a surface defined by the lattice webbing.

The wristbandmay have an elongate, rectangular shape with rounded ends. The wristbandmay include one or more edgesthat define a perimeter of the wristband. In the illustrated example, the edgeis a continuous edge having rounded corners and defining a substantially rectangular wristbandwith rounded ends. In other implementations, the wristbandmay have an edgewith square corners defining a rectangle having four sides. The one or more edgesmay have a thickness that extends a full depth of the wristband. The one or more edgesextending about the perimeter of the wristbandmay define an area within the perimeter of the edgeor edges.

The lattice webbingmay be formed from one or more layers of material extending between the one or more edgesacross at least a portion of the area defined by the perimeter edges. In some implementations, the lattice webbingmay be formed from a first lattice webbing() and a second lattice webbing(), which may be separated by an air gap. In the illustrated example, the lattice webbingmay be formed by a plurality of honeycomb-shapes arranged in a substantially repeating pattern across the area and along at least portion of the length. In other implementations, the lattice webbingmay be formed by one or more shapes in a regular, semi-regular, or random configuration. In still other implementations, the lattice webbingmay be customized to include at least one lattice webbinghaving a custom configuration.

In some implementations, the lattice webbing() and the lattice webbing() may be formed from elastomeric polymer having a shore A hardness in a range from approximately 65 to 77 and a tear strength of 20 kilo-Newtons per meter or more. Additionally, the 3D printing process may enable printing of a lattice webbingof printed shapes that may have spatially varying dimensions, including sizes, depths, and thicknesses. In some implementations, strands or elements within the lattice webbingmay have a thickness of approximately 0.6 mm, which may be too thin for manufacturing using injection molding or other plastic molding techniques with this type of elastic material.

In some implementations, the additive layering of the 3D printing process may produce layer lines, which are sometimes referred to as “Z-lines”. Such lines are not present in devices produced by injection molding. Z-lines are sometimes visible (particularly under magnification) along the sides and edges of a printed part. However, machine processing or ink printing can blur such lines. In some implementations, the Z-lines may be visible through x-ray scanning, microscopic inspection, and the like.

In this implementation, the wristbandmay include the lattice webbingmay extend as depicted inwith an air gapbetween the lattice webbing layers() and(). In some implementations, support structures may be formed to provide support between the lattice webbing layers() and(). The support structures may include arches, pillars, or various shapes that may allow for air gapsand that may provide lateral support for the lattice webbing.

depicts a side viewof the wristbandof. In this view, the postis shown to extend above the surface of the edgeof the wristband. Similarly, adjustment holes or openingsmay include a portion that may extend slightly past the surface of the edge. The holes or openingsmay be formed in the lattice webbingand may extend through one or more layers of the lattice webbing.

depicts a cross-sectional viewof the wristband taken along line C-C in, in accordance with certain embodiments. In this example, the wristbandmay include an edge. In this view, a first portion of the edge(first edge()) and a second portion of the edge(second edge()) are coupled by a first lattice webbing() and a second lattice webbing(), which are separated by an air gap.

In this example, the openingmay be formed from a first opening() in the first lattice webbing() and a second opening() in the second lattice webbing(). The first and second lattice webbings() and() may be separated from one another by a distance that defines an air gap.

In this example, the spacing between the first and second lattice webbings() and() may include an internal lattice, which may be compressible in one or more dimensions, and which may maintain a selected spacing under stress or pressure. The air gap(or air gaps) may exist within the internal lattice. The internal latticemay include one or more pillars, tendrils, or other shapes, at least some of which may extend between the first lattice webbing() and the second lattice webbing(). In this example, the internal latticemay include curved arches and straight truss shapes, which may extend perpendicular or at an angle between the first lattice webbing() and the second lattice webbing().

In the illustrated example of, the lattice webbing() has a substantially constant thickness from the first edge() to the second edge(). Similarly, the lattice webbing() has a substantially constant thickness from the first edge() to the second edge(). In other implementations, one or more of the lattice webbing() or the lattice webbing() may have a spatially variable thickness, which may be produced by individual elements of the lattice.

Additionally, the internal latticeis depicted as having a substantially constant thickness from the first lattice webbing() to the second lattice webbing(). However, the internal latticemay be comprised of structures having different shapes, different thicknesses, and different structural characteristics. In some implementations, one or more of the structures may vary in thickness or shape along its length. For example, one or more of the structures may have a slightly conical shape or may vary from a hexagonal cross-sectional shape to a rectangular cross-sectional shape along its length. Additionally, since the internal latticeis 3D printed, the composition of the one or more structures may vary between individual elements, within a single element along its length, or any combination thereof.

In some implementations, the angular orientation of selected shapes within one or more of the lattice webbingsor the internal latticemay vary, producing variability in the thickness of the lattice webbingand in the internal lattice. In other implementations, in addition to variability of the angular orientation, the shapes that comprise the lattice webbingmay vary. The thicknesses of the shapes, the sizes of the shapes, and their relative spacing may vary within a lattice webbing, between lattice webbings() and(), within the internal lattice, from wristbandto wristband, or any combination thereof.