Comfort fiber

Abstract

A method of producing a filament is disclosed. The method includes extruding a material for a filament core and a material for a filament sheath using an extruder, using a core portion and a sheath portion of a die in order to direct the material extruded from the extruder, and forming a filament by cooling during or after using the die. A method and apparatus for post-processing a 3D printed product using at least one of laser radiation or plasma processing is disclosed. In addition, a core / sheath structure composed of the forming material or a formed product produced from the forming material is disclosed. The core / sheath structure comprises a core and a sheath, the core and sheath comprising: one or both of fibers or particles; and at least one of: a soluble substance; an antimicrobial substance; an ultraviolet protection substance; an odor management substance; or a moisture management substance.

Description

(19) State Intellectual Property Office (12) Invention Patent Application (10) Application Publication Number (43) Application Publication Date (21) Application Number 202480027594.7 (22) Application Date 2024.02.22 (30) Priority Data 63 / 486385 2023.02.22 US (85) PCT International Application Entering National Phase Date 2025.10.20 (86) PCT International Application Application Data PCT / US2024 / 016885 2024.02.22 (87) PCT International Application Publication Data WO2024 / 178216 EN 2024.08.29 (71) Applicant: Muen Creative Labs, Inc. Address: California, USA (72) Inventors: N.Navi, G. Ottogust, D. Pellegrini, T. O'Hara (74) Patent Agency: China Patent Agency (Hong Kong) Limited 72001 Patent Attorneys Yu Miao and Zhang Hua (51) Int.Cl. B29C 48 / 05 (2006.01) B29C 48 / 30 (2006.01) B29C 48 / 78 (2006.01) D01D 5 / 088 (2006.01) D01D 5 / 34 (2006.01) D01H 1 / 541 (2006.01) D04H 3 / 16 (2006.01) B29C 48 / 41 (2006.01) B29C 48 / 455 (2006.01) (54) Invention Title: Comfort Fiber (57) Abstract: A method for producing filaments is disclosed. The method includes extruding material for a filament core and material for a filament sheath using an extruder, using the core and sheath portions of a die to guide the material extruded from the extruder, and forming a filament by cooling during or after the use of the die. A method and apparatus for post-processing 3D printed products using at least one of laser radiation or plasma treatment are disclosed. Additionally, a core / sheath structure consisting of a forming material or a formed product generated from the forming material is disclosed. The core / sheath structure includes a core and a sheath comprising: one or both of fibers or particles; and at least one of the following: a soluble substance; an antimicrobial substance; an ultraviolet-protective substance; an odor-managing substance; or a moisture-managing substance. Claims 3 pages, Description 42 pages, Drawings 33 pages, CN 121100052 A 2025.12.09 CN 1 21 10 00 52 A 1. A method for producing filaments, comprising: extruding a first set of materials for a filament core and a second set of materials for a filament sheath using one or more extruders, wherein the second set of materials comprises at least one or both of fibers or granules;1. Using a core portion and a sheath portion of at least one die to guide the first set of materials and the second set of materials extruded from the one or more extruders, respectively; and forming filaments by cooling the first set of materials and the second set of materials during or after using the core portion and the sheath portion of the at least one die. 2. The method of claim 1, wherein the one or more extruders comprise at least a first extruder for melting, mixing, and extruding the first set of materials and at least a second extruder for melting, mixing, and extruding the second set of materials; and wherein the at least second extruder comprises a twin-screw extruder. 3. The method of claim 2, wherein the second set of materials comprises at least one thermoplastic polymer and at least two of the fibers or granules. 4. The method of claim 3, wherein the second set of materials further comprises a water-soluble polymer. 5. The method of claim 3, wherein the diameter of the core portion of the at least one die is at least five times the thickness of the sheath portion of the at least one die. 6. A method for processing a 3D-printed product, the method comprising: receiving a 3D-printed product; and, after receiving the product, subjecting it to at least one of laser irradiation treatment or plasma treatment. 7. The method of claim 6, wherein the molded product comprises one or more layers; and wherein, after 3D printing the molded product, laser radiation is applied to the surface or interior of at least one of the one or more layers. 8. The method of claim 7, wherein the one or more layers comprise an outer layer having a surface configured to contact the skin of a user of the molded product; and wherein applying laser radiation comprises laser ablation, which patterns the surface of the outer layer to alter the sensation of the outer layer upon contact with the user's skin. 9. The method of claim 7, wherein the one or more layers comprise an outer layer having a surface configured to contact the skin of a user of the molded product; and wherein applying laser radiation alters the interior of the outer layer. 10. The method of claim 9, wherein applying laser radiation comprises laser ablation of at least a portion of the interior of the outer layer. 11. The method of claim 10, wherein the interior of the outer layer comprises one or both of at least one thermoplastic polymer and fibers or granules; and wherein laser ablation comprises removing at least a portion of the at least one thermoplastic polymer to enhance the effect on the skin of the user of the molded product. 12. The method of claim 7, wherein the one or more layers include an inner layer having a surface not configured to contact the skin of a user of the molded product; and wherein laser radiation is applied to the inner layer of the molded product. 13. The method of claim 12, wherein laser radiation is applied to the inner layer of the molded product to ablate at least a portion of the inner layer. 14. The method of claim 13, wherein ablation of the at least a portion of the inner layer alters the moisture content of the molded product. (Claims 1 / 3 page)2 CN 121100052 A Management or drape. 15. The method of claim 14, wherein the formed product comprises one or more layers; and wherein, after 3D printing the formed product, a plasma treatment is applied to the surface of at least one of the one or more layers. 16. The method of claim 15, wherein the plasma treatment cleans the surface of at least one of the one or more layers. 17. An apparatus configured to process a 3D printed formed product, the apparatus comprising: at least one of a laser irradiation device or a plasma treatment device, configured to receive a formed product 3D printed by at least one 3D printer; and at least one controller configured to control at least one of the laser irradiation device or the plasma treatment device to apply laser irradiation or plasma treatment to the formed product. 18. The apparatus of claim 17, wherein the formed product comprises one or more layers; and wherein the at least one controller is configured to control the laser irradiation device to apply laser irradiation to the surface or interior of at least one of the one or more layers. 19. The apparatus of claim 18, wherein the one or more layers comprise an outer layer having a surface configured to contact the skin of a user of the molded product; and wherein the at least one controller is configured to control a laser radiation device to apply laser radiation by laser ablation, which forms a pattern on the surface of the outer layer to alter the sensation of the outer layer upon contact with the user's skin. 20. The apparatus of claim 18, wherein the one or more layers comprise an outer layer having a surface configured to contact the skin of a user of the molded product; and wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to alter the interior of the outer layer. 21. The apparatus of claim 20, wherein the at least one controller is configured to control a laser radiation device to apply laser radiation by laser ablation of at least a portion of the interior of the outer layer. 22. The apparatus of claim 21, wherein the interior of the outer layer comprises at least one thermoplastic polymer and one or both of fibers or granules; and wherein the at least one controller is configured to control a laser radiation device to remove at least a portion of the at least one thermoplastic polymer to enhance the effect on the user's skin of the molded product. 23. The apparatus of claim 18, wherein the one or more layers include an inner layer having a surface not configured to contact the skin of a user of the molded product; and wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to the inner layer of the molded product. 24. The apparatus of claim 23, wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to the inner layer of the molded product to ablate at least a portion of the inner layer.25. The apparatus of claim 24, wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to alter at least one of moisture management or drape of the molded product. 26. The apparatus of claim 17, wherein the molded product comprises one or more layers; and wherein the at least one controller is configured to control a plasma processing device to apply plasma processing to the surface of at least one of the one or more layers. Claims 2 / 3 Page 3 CN 121100052 A 27. A core / sheath structure comprising a molding material or a molded product formed from the molding material, the core / sheath structure comprising: a core having a linear shape and an outer peripheral surface and comprising at least one thermoplastic polymer; and a sheath at least partially covering the outer peripheral surface and comprising: (i) one or both of fibers or granules; and (ii) at least one of the following: a soluble substance; an antimicrobial substance; an ultraviolet-protective substance; an odor-managing substance; or a moisture-managing substance. 28. The core / sheath structure of claim 27, wherein the core / sheath structure is configured for 3D printing; and wherein the sheath comprises a water-soluble substance. 29. The core / sheath structure of claim 28, wherein the water-soluble substance comprises polyvinyl alcohol. Claims 3 / 3 Page 4 CN 121100052 A Comfort Fiber

[0001] Reference to Related Applications This application claims priority to U.S. Provisional Application No. 63 / 486,385 (filed February 22, 2023), the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to core / sheath structures, methods of manufacturing flocked products, and flocked products. These flocked products are filaments that can be made or formed (e.g., woven) into textiles having desired properties. Background Art

[0003] This section is intended to introduce various aspects of the art that may be related to exemplary embodiments of this disclosure. It is believed that this discussion helps to provide a framework for a better understanding of specific aspects of this disclosure. Therefore, it should be understood that this section should be understood in this context and not necessarily as an admission of prior art.

[0004] U.S. Patent Application Publication No. 2017 / 0268133 discloses a consumable filament. Consumable filaments are melted and extruded in an additive manufacturing system. The consumable filaments include a core portion and a sheath portion enclosing the core portion. The core portion includes a matrix of a first base polymer and particles dispersed in the matrix. The sheath portion includes a second base polymer. The particles of the core portion are selected from metallic particles, non-metallic particles, magnetic particles, and combinations thereof, and may be ferrite particles (paragraph

[0005] ). The particles of the core portion do not penetrate the outer surface of the sheath portion (paragraph

[0074] ). Summary of the Invention

[0005] In one or more embodiments, a method for producing filaments is disclosed. The method includes: using a orMultiple extruders extrude a first set of materials for a filament core and a second set of materials for a filament sheath, wherein the second set of materials comprises at least one or both of fibers or granules; a core portion and a sheath portion of at least one die are used to guide the first set of materials and the second set of materials extruded from the one or more extruders, respectively; and a filament is formed by cooling the first set of materials and the second set of materials during or after the use of the core portion and the sheath portion of the at least one die.

[0006] In one or more embodiments, a method for processing a 3D-printed product is disclosed. The method includes: receiving a 3D-printed product; and, after receiving the product, subjecting it to at least one of laser irradiation treatment or plasma treatment.

[0007] In one or more embodiments, an apparatus configured to process a 3D-printed product is disclosed. The apparatus includes: at least one of a laser irradiation device or a plasma treatment device configured to receive a product 3D-printed by at least one 3D printer; and at least one controller configured to control at least one of the laser irradiation device or the plasma treatment device to apply laser irradiation or plasma treatment to the product.

[0008] In one or more embodiments, a core / sheath structure comprising a molding material or a molded product formed from the molding material is disclosed. The core / sheath structure comprises: a core having a linear shape and an outer peripheral surface and comprising at least one thermoplastic polymer; and a sheath at least partially covering the outer peripheral surface and comprising: (i) one or both of fibers or granules; and (ii) at least one of the following: a soluble substance; an antimicrobial substance; an ultraviolet protection substance; an odor management substance; or a moisture management substance. Brief Description of the Drawings

[0009] In the following detailed description, the present application is further described by way of non-limiting embodiments of exemplary implementations with reference to the pointed-out figures, wherein the same reference numerals represent similar parts in several views of the figures. For this purpose, the figures only illustrate exemplary embodiments and should not be regarded as limiting the scope, as the present disclosure may allow for other equally effective embodiments and applications.

[0010] FIG1 is a perspective view schematically illustrating a molding material of a first embodiment.

[0011] FIG2 is a schematic cross-sectional view showing the molding material of the first embodiment.

[0012] FIG3 is a cross-sectional photograph of a prototype of the molding material of the first embodiment.

[0013] FIG4 is a schematic cross-sectional view showing a variant of the molding material of the first embodiment.

[0014] FIG5 is a schematic top view showing the molded product of the second embodiment.

[0015] FIG6 is a schematic cross-sectional view showing the linear body provided in the molded product of the second embodiment.

[0016] Figure 7 is a scanning electron microscope (SEM) micrograph of the entire cross-section of the linear body provided in the molded product prototype of the second embodiment.

[0017] Figure 8 is an SEM micrograph of the cross-sectional periphery of the linear body provided in the molded product prototype of the second embodiment.

[0018] Figure 9 is a schematic enlarged cross-sectional view near the interface between the molded product of the second embodiment and human skin in contact with the molded product.

[0019] Figure 10 is an SEM micrograph of the cross-section of the prototype of the molded product of the second embodiment.

[0020] Figure 11 is an SEM micrograph of the cross-section of the prototype of the molded product of the second embodiment.

[0021] Figure 12 is an SEM micrograph of the cross-section of the prototype of the molded product manufactured using monofilament.

[0022] Figure 13 is an SEM micrograph of the cross-section of the prototype of the molded product manufactured using monofilament.

[0023] Figure 14 is an SEM micrograph of the upper surface of the prototype of the molded product manufactured using monofilament.

[0024] FIG15 is an SEM micrograph of the upper surface of a prototype of a molded product made using monofilament.

[0025] FIG16 is an SEM micrograph of a prototype of a molded product made using a molding material of a variant of the first embodiment.

[0026] FIG17 is a micrograph of a monofilament made of polyester.

[0027] FIG18 is a micrograph of a multifilament made of polyester.

[0028] FIG19 is a side view schematically showing a three-dimensional (3D) printer used to manufacture a molded product of the second embodiment.

[0029] FIG20 is a top view schematically showing a flocked product of the third embodiment.

[0030] FIG21 is an enlarged cross-sectional view schematically showing the interface between the molded product of the third embodiment and human skin in contact with the molded product.

[0031] FIG22 is a perspective view schematically showing an electrostatic deposition apparatus used to manufacture a flocked product of the third embodiment.

[0032] FIG23 is a flowchart showing the process of manufacturing a flocked product of the third embodiment.

[0033] Figure 24 is a photograph of a prototype of the body provided in the flocked product of the third embodiment.

[0034] Figure 25 is a photograph of a prototype of the flocked product of the third embodiment.

[0035] Figure 26 shows a comparative cross-sectional view of modern filaments and comfort fibers. Specification 2 / 42 pages 6 CN 121100052 A

[0036] Figure 27A shows a cross-section of a comfort fiber with a medium load of particles in its associated sheath layer.

[0037] Figure 27B shows a cross-section of a comfort fiber with a high load of particles in its associated sheath layer.

[0038] Figure 28 is a flowchart depicting a method for manufacturing comfort fibers and making clothing articles from comfort fibers.

[0039] Figures 29A-B depict TPU-based monofilaments.

[0040] Figures 30A-B depict core / sheath filaments with cotton powder in the sheath layer.

[0041] Figures 31A-B depict enlarged views of the outer surface of a core / sheath filament with cotton particles in the sheath at different scales.

[0042] Figures 32A-B depict core / sheath filaments with wool particles in the sheath.

[0043] Figures 33A-B depict enlarged views of the outer surface of a core / sheath filament with wool particles in the sheath.

[0044] Figures 34A-B depict cross-sectional views of a 3D-printed fabric based on core / sheath filaments with cotton particles in the sheath (e.g., comfort filaments).

[0045] Figures 35A-B depict cross-sectional views of a 3D-printed fabric based on core / sheath filaments with cotton particles in the sheath (e.g., comfort filaments).

[0046] Figures 36A-B depict printed fabrics based on TPU monofilaments.

[0047] Figures 37A-B depict cross-sectional views of printed fabrics based on the TPU monofilaments shown in Figures 36A-B.

[0048] Figure 38 depicts the final product (e.g., printed fabric) based on core / sheath filaments (e.g., comfort fibers) with cotton particles in the sheath.

[0049] Figure 39 is a table summarizing the tensile test results at 100%, 200%, and 300% elongation under standard conditions (23°C, 50% RH).

[0050] Figure 40 is a table summarizing the tensile test results for chemical resistance to seawater and chlorinated water, considering the modulus (recorded stress) at 100%, 200%, and 300% elongation as a measure of chemical resistance.

[0051] Figure 41 is a table showing the moisture levels of different comfort filaments at different exposure times.

[0052] Figure 42 is a block diagram of an example system for filament production.

[0053] Figure 43 is an example flow diagram of filament production.

[0054] Figure 44 is a block diagram of an example system for applying laser radiation.

[0055] Figure 45 is an example flow diagram of laser ablation.

[0056] FIG46 is a block diagram of an example plasma processing system.

[0057] FIG47 is an example flowchart of plasma processing.

[0058] FIG48 is a diagram of an exemplary computer system that can be used to implement the methods described herein. Detailed Description

[0059] The methods, apparatuses, systems and other features discussed below can be embodied in a variety of different forms. However, not all of the components described are necessary, and some embodiments may include more, different or fewer components than those explicitly described in this disclosure. Changes may be made to the arrangement and type of components without departing from the spirit or scope of the claims described herein. Furthermore, changes may be made to the described methods without departing from the spirit or scope of the claims described herein, including adding, deleting or rearranging the order of logical operations.

[0060] It should be understood that this disclosure is not limited to a particular apparatus or method, which of course can vary. It should also be understood thatThe terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “an,” “a,” and “the” include both singular and plural references unless expressly stated otherwise. Furthermore, the terms “may” and “possibly” are used throughout this application to mean permissible (i.e., possible, able) rather than mandatory (i.e., required). The term “comprising” and its derivatives mean “including, but not limited to.” The term “joint” means directly or indirectly connected. The term “exemplary” as used herein means “as an example, instance, or illustration.” Any aspect described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects. The term “uniform” means substantially the same for each sub-element, with a variation range of approximately ±10%. The term “substantially” means within a range of variation not exceeding ±10%, such as not exceeding ±9%, not exceeding ±8%, not exceeding ±7%, not exceeding ±6%, not exceeding ±5%, not exceeding ±4%, not exceeding ±3%, not exceeding ±2%, and not exceeding ±1%.

[0061] As used herein, “acquired” data generally refers to any method or combination of methods for acquiring, collecting, or accessing data, including, for example, directly measuring or sensing physical properties, receiving transmitted data, selecting data from a set of physical sensors, identifying data in a data record, and retrieving data from one or more databases.

[0062] Terms such as “continuous” and “enduring” as used herein generally refer to a process that repeats over time independently of an external trigger that causes subsequent repetitions. In some cases, a continuous process may repeat in real time with very short periods of inactivity between repetitions. In some cases, the inactivity period may be inherent to the continuous process.

[0063] If there is any conflict between the use of words or terms in this specification and in one or more patents or other documents that may be incorporated herein by reference, the definitions consistent with this specification shall be adopted in order to understand this disclosure.

[0064] 3D printing can be performed in one of several ways. In one way, 3D printing may include an extrusion printing process. For example, fused deposition modeling (FDM) can use filaments, such as those disclosed in U.S. Patent Application Publication No. 2017 / 0268133, or consumable filaments, as discussed in the background section.

[0065] In the context of filaments, when molded products are manufactured using consumable filaments (such as those disclosed in U.S. Patent Application Publication No. 2017 / 0268133), the molded products may have a rubbery or plastic-like feel, and may not have a comfortable feel. In this regard, molded products or flocked products with a comfortable feel are disclosed in one or more embodiments.

[0066] In one or more embodiments, a forming material (e.g., a filament for a 3D printer) is disclosed, comprising a core and one or more sheaths (e.g., one or more shells). In one or more embodiments, the sheath comprises one or both of fibers or particles. As discussed in more detail below, the fibers and / or particles in the sheath, as segments and / or separate layers and / or protruding from the outer surface of the core and thus closer to the user's skin than the core, can impart properties to the forming material. Thus, in one or more embodiments, the one or more sheaths may comprise at least one material different from the material in the core (e.g., fibers and / or particles). Alternatively, one or more materials in the sheath may be contained within the core.

[0067] In one or more embodiments, the forming material can then be used to produce a formed product. As discussed in more detail below, a formed product can be produced from the forming material in one of a variety of ways, such as: using the forming material as a filament for 3D printing to produce the formed product; knitting, weaving, and / or sewing the forming material; etc. In either case, the formed product typically retains the core / sheath structure of the underlying forming material. For example, in the case of 3D printing, a molded product may include one or more layers (interchangeably referred to as printing layers), which typically retain a core / sheath structure, although some modifications may be possible. In one particular modification, the one or more layers may have a different diameter than the molding material (e.g., the diameter of the one or more layers may be smaller than the diameter of the molding material: see Figures 27A-B, where the diameter of the printing layer is reduced from 1.75 mm to 0.4 mm, effectively reducing the size by at least 1 / 4). In another particular modification, the outer surface of the one or more layers may be different from the outer surface of the molding material (e.g., one or more materials in the sheath layer, such as fibers and / or particles, may protrude from the outer surface of the layer (see Figures 27A-B), which may be beneficial to the user of the molded product). Thus, a molded product may consist of one or more layers having a core / sheath structure, as discussed further below. Specification 4 / 42 pages 8 CN 121100052 A

[0068] In one or more embodiments, various materials in the molding material sheath are considered, which may in turn affect the molded product. As an example, the sheath may use the same or a different type of thermoplastic polymer as the core. As another example, the core may include fibers and / or particles, which may be: (i) the same or a different type as the fibers and / or particles in the sheath; or (ii) the same or a different concentration of fibers and / or particles in the sheath. In this regard, in one embodiment, the sheath is formed separately from the core and includes fibers and / or particles that can impart desired properties to the forming material, which may differ from the properties imparted by the core itself. Alternatively, the sheath may be formed from fibers and / or particles protruding from the core.

[0069] Therefore, various methods are considered for making the fibers and / or particles visible in the sheath. In one or more embodiments, the fibers and / or particles may be located within a material separate from the core (and placed on the outer surface of the core). For example, the core may contain at least one thermoplastic polymer (e.g., a single thermoplastic polymer), and the one or more sheaths may contain fibers and / or particles located within or on at least one thermoplastic polymer, which at least partially surrounds the core (e.g., at least partially surrounds a single sheath containing one or both of the thermoplastic polymer and fibers or particles). In this way, the fibers and / or particles may be suspended in and / or on another medium (e.g., a thermoplastic polymer similar to or the same as the core, or a material other than a thermoplastic polymer). In one embodiment, the at least one thermoplastic layer of the core is the same as the at least one thermoplastic layer of the sheath. Alternatively, the at least one thermoplastic layer of the core differs from the at least one thermoplastic layer of the sheath in one or more aspects (e.g., different Shore A values). In any case, the fibers and / or particles as part of the sheath may impart different properties to the thermoplastic elastomer of the core.

[0070] Instead of fibers and / or particles within a material separate from the core (and located on the outer surface of the core), the fibers and / or particles in the sheath can be placed directly on the surface. As an example, fibers and / or particles can be sprayed onto the outer surface of the core using an adhesive. In this respect, the sheath consists of fibers and / or particles (and optionally an adhesive) placed on the outer surface of the core, without any intermediate material (e.g., a thermoplastic layer) to suspend them therein. In a particular non-limiting example, flocked fibers can be deposited (e.g., flocked) onto the outer surface of the core once they emerge from the die, and an adhesive (e.g., a thermoplastic emulsion) is used to bond the fibers until printing. As another example, fibers and / or particles can be sprayed onto the outermost surface of the sheath along with an adhesive. Again, in this way, the fibers and / or particles can come into contact with the user's skin and thus can impart properties different from those of the core and / or any intermediate sheath.

[0071] Therefore, in one or more embodiments, the sheath may be composed of any one, any combination of, or all of the following substances: (i) a plastic polymer (e.g., a thermoplastic polymer); (ii) fibers and / or granules; (iii) a soluble substance (e.g., a water-soluble substance, such as a water-soluble synthetic polymer (e.g., polyvinyl alcohol (PVA)); (iv) an antimicrobial substance (e.g., any one, any combination of, or all of antibacterial, antifungal, and antiviral); (v) sunlight or ultraviolet protection factor (UPF) protection (e.g., zinc oxide); (vi) odor management (e.g., zinc oxide; coffee powder); or (vii) moisture management (e.g., coffee powder). In this respect, because the respective components of (i)-(vii) can be included in the sheath (and in one embodiment, only in...)(in the sheath), so the amount of each component required to achieve acceptable results may be less than when the components are included in the core, which is particularly advantageous, especially for more expensive materials (e.g., wool).

[0072] As an example, the sheath may be composed of (or consist of) a plastic polymer, fibers and / or granules, and a soluble substance. As another example, the sheath may be composed of (or consist of) a plastic polymer and a soluble substance. In either case, for a sheath composed at least partially of a soluble material (e.g., a water-soluble material), the formed product may be post-processed after 3D printing to remove at least some of the soluble material.

[0073] Different percentages of TPU and fibers / granules are considered. In one or more embodiments, the percentage of TPU may be greater than the percentage of fibers / granules. As an example, the percentage of TPU may be at least two times, at least three times, at least four times, or at least five times the percentage of fibers / granules.

[0074] In the case of a sheath containing a water-soluble material, post-treatment of the molded product may include exposing the molded product to water (e.g., washing the molded product with water). During washing, some or all of the water-soluble material may be removed from the sheath, which may enhance the fibers and / or particles in the sheath or make the fibers and / or particles more effective on the skin (e.g., the skin feels softer).

[0075] Different percentages of TPU, PVA, and fibers / particles are considered. In one or more embodiments, the percentage of TPU may be greater than each of the percentages of PVA and fibers / particles. Alternatively, the percentage of TPU may be greater than the sum of the percentages of PVA and fibers / particles. Alternatively, the percentage of TPU may be equal to (or less than) the percentage of fibers / particles. In this respect, depending on the selected percentages, the molded product may be more durable or less durable, more brittle or less brittle, more resilient or less resilient, etc.

[0076] As an example, in one or more embodiments, the sheath may include a thermoplastic polymer, fibers and / or particles, and PVA material. After 3D printing, the formed product can be exposed to water to break down some or all of the PVA in the sheath. In this respect, with the removal of PVA, the effect of the fibers and / or particles in the sheath on the wearer's skin may be further enhanced.

[0077] As described above, the forming material can be used in one of a variety of ways for 3D printing and / or non-3D printing to generate the formed product. For example, in one or more embodiments, the forming material (e.g., a filament having a core / sheath) can be introduced directly into a 3D printer to 3D print the formed product. Thus, the formed product can consist of one or more layers (interchangeably referred to as 3D printed layers), wherein at least one, at least some, or all of the one or more layers have a core / sheath structure (having the characteristics described herein).(The core and / or sheath have one, some, or all of the features described). In this regard, 3D printers can utilize molding materials to generate layered molded products with a core / sheath structure, thereby imparting the benefits of the core / sheath structure. For example, a core / sheath structure allows various materials to be contained within the sheath, such as fibers and / or particles, which can allow for the use of fewer fibers and / or particles (because fibers and / or particles are not contained in the core or constitute a lower percentage of the core) while still retaining the benefits of fibers and / or particles (e.g., fibers and / or particles can come into contact with the skin). Therefore, in one or more embodiments, the molded product can be printed entirely from a molding material with a core / sheath structure, such that all layers of the molded product have a core / sheath structure. Alternatively, the molded product can also be printed from a first molding material with a core / sheath structure and a second molding material with a core structure (without a sheath), such that one or more layers of the molded product have a core / sheath structure (e.g., an outer layer that can come into contact with the skin), while other layers of the molded product have a core structure (e.g., an inner layer that does not come into contact with the skin).

[0078] As another example, a molded product can be formed using a molding material (e.g., by knitting, weaving filaments, etc.) without 3D printing. The molding material used in this manner can be combined in one of a variety of ways (e.g., knitting or weaving different filaments together), for example, by applying heat and / or applying an adhesive. Similarly, a molded product can also be generated entirely from a molding material having a core / sheath structure, such that all layers of the molded product have a core / sheath structure. Alternatively, a molded product can be generated from a first molding material having a core / sheath structure and a second molding material having a core structure (without a sheath), such that one or more layers of the molded product have a core / sheath structure (e.g., an outer layer that can contact the skin), while other layers of the molded product have a core structure (e.g., an inner layer that cannot contact the skin). In any case, a molded product (similar to a 3D-printed molded product) may have a core / sheath structure in one or more of its layers.

[0079] In one or more embodiments, after the formed product is produced (e.g., using 3D printing or not using 3D printing), one or more additional processes or treatments may be performed, including any one, any combination of, or all of flocking, laser irradiation treatment (e.g., laser ablation), or plasma treatment.

[0080] Thus, in one or more embodiments, flocking may be performed, wherein flocking (e.g., fibers) may be attached or bonded to the surface of the formed product. For example, flocking may be bonded to a surface including an adhesive by abutting and / or piercing the surface of the formed product. In the case of abutting and / or piercing, external force may be applied, for example by electrostatic deposition equipment.

[0081] In one or more embodiments, laser radiation treatment (e.g., laser ablation) can be used to process shaped products (e.g., after 3D printing or after knitting and / or weaving filaments together). Specifically, the shaped product may include one or more layers, such as an outer layer (e.g., whose outer surface may contact the user's skin) and an inner layer (e.g., whose surfaces do not contact the user's skin). In one or more embodiments, one or more lasers can be used to apply laser radiation (e.g., to perform laser ablation), wherein the laser radiation is applied to said one or more layers. As an example, laser radiation may be applied to one or more portions of the outer layer, such as the outer surface of the outer layer (which may contact the user's skin) or the inner portion of the outer layer, or both. Specifically, laser radiation (e.g., laser ablation) may be applied to the surface of the outer layer (e.g., the surface of the sheath of the outer layer in a core / sheath structure of the shaped product; or the surface of the core of the outer layer in a core structure (without a sheath) of the shaped product) to ablate patterns or other markings on the surface of the outer layer. Alternatively or additionally, laser radiation (e.g., laser ablation) may be applied to the interior of the outer layer (e.g., in the sheath of the outer layer in a core / sheath structure of a molded product; in the core of the outer layer in a core / sheath structure of a molded product; or in the core of the outer layer in a core structure (without a sheath) of a molded product), wherein the laser radiation alters the interior of the outer layer in one of a variety of ways (e.g., ablates or removes material, such as TPU, in the sheath and / or core to highlight other materials, such as fibers / particles, in the sheath and / or core; and / or uses laser radiation to activate material within the sheath and / or core).

[0082] Alternatively or additionally, as another example, laser radiation may be applied to one or more portions of the inner layer of a molded product, such as one or both of the outer surface or interior of the inner layer. Specifically, laser radiation (e.g., laser ablation) can be applied to the interior of the inner layer (e.g., in the sheath of the inner layer in a core / sheath structure of a molded product; in the core of the inner layer in a core / sheath structure of a molded product; or in the core of the inner layer in a core structure (without a sheath) of a molded product), wherein the laser radiation alters the interior of the outer layer in one of a variety of ways (e.g., ablation or removal of material, such as TPU, in the sheath and / or core to highlight other materials, such as fibers / particles, in the sheath and / or core; and / or activation of material within the sheath and / or core using laser radiation). In this way, laser radiation can be used to alter properties of the molded product, such as moisture management (e.g., wicking and moisture uptake) and drape.

[0083] In one or more embodiments, plasma treatment can be used to process the molded product (e.g., after 3D printing or after knitting and / or weaving filaments together). Specifically, plasma surface treatment can be used to alter the surface properties of the molded product, such as surface energy, functionalization, and surface cleaning (e.g., removal of contaminants).

[0084] First Embodiment1. Overview of Molding Material Referring to the accompanying drawings, FIG1 is a perspective view schematically showing the molding material of the first embodiment. FIG2 is a cross-sectional view schematically showing the molding material of the first embodiment. FIG3 is a cross-sectional photograph of a prototype of the molding material of the first embodiment.

[0085] In one or more embodiments, the molding material 1 of the first embodiment shown in FIG1, FIG2 and FIG3 can be used to manufacture a molded product. Consider various molded products. As an example, the molded product can be a flat shape, similar to a piece or piece of fabric. In this form, the molded product can be further processed, such as additional cutting or bonding (e.g., connecting with other fabrics formed by the molding material 1, or connecting with other fabrics not formed by the molding material), so that the molded product can be transformed into a commercially available article (e.g., shirt, trousers, handbag, etc.). As another example, the molded product can include a final product for sale (e.g., shirt, trousers, handbag, etc.) or can include a near-final product for sale (e.g., after additional processing, including flocking, laser ablation). In this respect, the molded product can take one of several forms and can be used at various steps of the manufacturing process.

[0086] When the molded product is manufactured using the molding material 1, the molding material 1 can be melted, the molten molding material can be shaped, and the shaped molding material can be solidified. In this respect, the molded product, which is a melted and solidified product of the molding material 1, can be manufactured in one or more embodiments. Therefore, the molding material 1 can include consumables consumed for manufacturing the molded product.

[0087] In one or more embodiments, the molding material 1 can be used, for example, to manufacture the molded product by a three-dimensional (3D) printer, and can be used to manufacture the molded product by a fused filament manufacturing (FFF) method or a fused deposition modeling (FDM) method. However, in alternative embodiments, the molding material 1 can be used to manufacture the molded product by a molding apparatus other than a 3D printer, or can be used to manufacture the molded product by a molding method other than the FFF method or the FDM method.

[0088] In one or more embodiments, the molding material 1 has a linear shape and / or has thermoplasticity. In one or more embodiments, when the molded product is manufactured using the molding material 1, it can be heated while being conveyed along its length. This allows the molding material 1 to be melted. In one or more embodiments, the molding material 1 is flexible and elastic. Molding material 1 with these properties may also be referred to as a filament. In one or more embodiments, when the molding material 1 is used to manufacture a molded product via a 3D printer, the molding material 1 has a circular cross-sectional shape and possesses...Suitable diameter for 3D printers. The diameter of molding material 1 is, for example, 1.75 mm or 2.85 mm. See Figures 27A-B, which show a molding material with a diameter of 1.75 mm. However, molding material 1 may also have a cross-sectional shape other than a circular cross-section, and its diameter may also be a diameter other than 1.75 mm or 2.85 mm. As an example, a circular cross-sectional shape may be less than 1.75 mm. As another example, a circular cross-sectional shape may be greater than 2.85 mm. As another example, a circular cross-sectional shape may be between 1.75 mm and 2.85 mm.

[0089] In one or more embodiments, the main body portion of molding material 1 is thermoplastic. Thus, molding material 1 can be melted and separated into multiple components. Furthermore, new molding materials or other types of products can be manufactured from molding material 1. Therefore, molding material 1 can be reused.

[0090] In one or more embodiments, molding material 1 is sold in the homemade (do-it-yourself or DIY) market to consumers who can make the molded products themselves. Alternatively, or in addition, the molded product manufactured using molding material 1 can be sold to ordinary consumers in ordinary stores and ordinary markets.

[0091] 2. The cross-sectional structure and material properties of the molding material are shown in Figures 1, 2, and 3. The molding material 1 can be composed of a core / sheath structure 101 including a core 111 and a sheath 112, and can have a double-layer structure. The sheath 112 can also be called a shell. The core / sheath structure 101 can also be called a core / shell structure. Alternatively, the molding material 1 can also have a multi-layer structure, having a three-layer structure or more. The molding material 1 with a multi-layer structure having two or more layers (e.g., a three-layer structure, a four-layer structure, a five-layer structure, etc.) can also be called a multi-layer filament. In contrast to a multi-layer filament, the molding material with a single-layer structure can be called a monofilament.

[0092] As an example, a three-layer structure may include a core (e.g., core 111), a first sheath, and a second sheath, wherein the first sheath is coaxial with the core and the second sheath and is located between the core and the second sheath. As another example, the four-layer structure may include a core (e.g., core 111), a first sheath, a second sheath, and a third sheath, wherein the first sheath is coaxial with the core and the second sheath and is located between the core and the second sheath, and the second sheath is coaxial with the core and the third sheath and is located between the core and the third sheath.

[0093] In one or more embodiments, the core 111 has a linear shape. Furthermore, in one or more embodiments, the core 111 is flexible. In one aspect, the core 111 may be flexible, for example comprising a material having a lower Young's modulus and / or a lower hardness (e.g., 75 Shore A or lower; 70 Shore A or lower; 65 Shore A or lower; 60 Shore A or lower; etc.). Specification 8 / 42 pages 12 CN 121100052 A As shown in Figures 1 and 2, the core 111 has a circular cross-sectional shape. Other cross-sectional shapes (e.g., oval, elliptical) are also considered.(etc.). In this respect, the core 111 may have a cross-sectional shape other than a circular cross-section. In one or more embodiments, the sheath 112 covers the outer peripheral surface 111S of the core 111. Thus, the sheath 112 may be an outer layer located radially outward of the core 111, and is the outermost layer disposed radially outward of the forming material 1. In this respect, the sheath 112 at least partially covers the outer peripheral surface 111S of the core 111. In this respect, in one or more embodiments, the sheath 112 may cover the entire outer peripheral surface 111S (e.g., 100% of the entire outer peripheral surface 111S). Alternatively, the sheath 112 may cover at least a portion (but not all) of the entire outer peripheral surface 111S (e.g., the sheath 112 may cover at least or more than 50% of the entire outer peripheral surface 111S; the sheath 112 may cover at least 60% of the entire outer peripheral surface 111S; the sheath 112 may cover at least 70% of the entire outer peripheral surface 111S; the sheath 112 may cover at least 75% of the entire outer peripheral surface 111S; the sheath 112 may cover at least...). 80%; the sheath 112 may cover at least 85% of the entire peripheral surface 111S; the sheath 112 may cover at least 90% of the entire peripheral surface 111S; the sheath 112 may cover at least 95% of the entire peripheral surface 111S; the sheath 112 may cover at least 96% of the entire peripheral surface 111S; the sheath 112 may cover at least 97% of the entire peripheral surface 111S; the sheath 112 may cover at least 98% of the entire peripheral surface 111S; the sheath 112 may cover at least 99% of the entire peripheral surface 111S.

[0094] As shown in FIG2, the core 111 includes a first thermoplastic polymer 121. The sheath 112 includes a second thermoplastic polymer 122 and one or both of fibers or granules (hereinafter referred to as fibers / granules 123, any reference to fibers / granules 123 refers to one or both of fibers or granules). Thus, in one or some embodiments, fibers and granules may comprise separate forms. In one or more embodiments, the fibers can be characterized in one of a variety of ways, such as based on their shape. For example, fibers may comprise bundles of material having an elongated cylindrical shape, a relatively small diameter (D) (or width) and a relatively long length (L), thus resulting in a high L / D ratio (e.g., at least 5; at least 10; at least 15; etc.). In one or more embodiments, the particles can be characterized by their shape, such as spherical, cubic, rectangular, or irregular. In one or more embodiments, the sheath 112 comprises only particles. Alternatively, the sheath 112 comprises only fibers. Alternatively, both particles and fibers are contained in the sheath 112. Furthermore, in one or more embodiments, the fibers may: comprise natural materials (or be composed of natural materials); comprise synthetic materials (or be composed of synthetic materials); or comprise both natural and synthetic materials (or be composed of both natural and synthetic materials).Composition). Similarly, in one or more embodiments, the particles may: comprise natural materials (or be composed of natural materials); comprise synthetic materials (or be composed of synthetic materials); or comprise both natural and synthetic materials (or be composed of both natural and synthetic materials). In one or more embodiments, the selection of one or both of the materials in the fibers or particles may be based on the desired final feel of the final product (e.g., whether the final product is a fabric or a wearable product, such as a shirt, skirt, pants, handbag, etc.).

[0095] In one or more embodiments, the second thermoplastic polymer 122 is the matrix. Fibers / particles 123 are dispersed in the second thermoplastic polymer 122, which serves as the matrix. In one or more embodiments, the dispersion and / or distribution of the fibers / particles 123 in the second thermoplastic polymer 122 may depend on one or more aspects of the extruder / mixing process. In one or more embodiments, the fibers / particles 123 may be uniformly dispersed and / or uniformly distributed throughout the second thermoplastic polymer 122. Alternatively, the fibers / particles 123 may be randomly dispersed and / or randomly distributed throughout the second thermoplastic polymer 122. In one or more embodiments, the fiber / particle 123 may be at least partially embedded, contained in, or buried within the second thermoplastic polymer 122 at one end, with the opposite end of the fiber / particle 123 protruding from the second thermoplastic polymer 122. In this way, the fiber / particle 123 can form protrusions on the surface of the molded product to be produced, and impart a comfortable tactile feel to the molded product. Furthermore, the portion of the fiber / particle 123 embedded or located within the second thermoplastic polymer 122 may contribute to the moisture management properties associated with the second thermoplastic polymer 122.

[0096] In one or more embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are the main components of the core 111 and sheath 112, respectively, as described on page 9 / 42 of the specification, CN 121100052 A.

[0097] In one or more embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be the same type of thermoplastic polymer. Alternatively, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be different types of thermoplastic polymers. Therefore, in one or more embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are composed of the same polymer (e.g., the same type of polymer). Specifically, in one or more embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be identical in all respects. Alternatively, some, but not all, properties of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be identical, such as any one, any combination, or all of the following: same type; same grade; same structure; same hardness; same mechanical properties; same density;Same rheological properties; same crystallinity, etc.

[0098] Alternatively, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may comprise different polymers (e.g., polymers of different types). Specifically, in one or more embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be different in all respects. Alternatively, some, but not all, properties of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be different, for example, any one, any combination, or all of the following: different types; different grades; different structures; different hardness; different mechanical properties; different densities; different rheological properties; different crystallinity, etc.

[0099] In one or more embodiments, each of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be a single thermoplastic polymer. Alternatively, one or both of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be a mixture of two or more thermoplastic polymers.

[0100] In one or more embodiments, one, some, or each thermoplastic polymer may comprise, for example, one or both of a rigid component and a flexible component. Therefore, in one embodiment, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 each comprise a flexible component. Alternatively, in one or more embodiments, the thermoplastic polymers may comprise a more rigid component and a less rigid component (or, in other words, a less flexible component and a more flexible component).

[0101] In one or more embodiments, the more rigid component (e.g., the rigid component) may comprise, for example, a thermoplastic resin. Various thermoplastic resins are considered. For example, thermoplastic resins may comprise any one, any combination of, or all of the following: acrylonitrile butadiene styrene (ABS); polylactic acid (PLA); polyethylene terephthalate (PET) and other derivatives of polyesters; polycarbonate (PC); polyvinyl alcohol (PVA); polyamide (PA); styrene-based polymers; polyvinyl chloride (PVC); acrylic polymers; and polyolefins, such as polyethylene, polypropylene, copolymers thereof, and combinations thereof. Other thermoplastic resins are considered.

[0102] In one or more embodiments, the less rigid component (e.g., the flexible component) comprises, for example, a thermoplastic elastomer. In one or more embodiments, the thermoplastic elastomer (e.g., thermoplastic rubber) may comprise a physical mixture of copolymers or polymers (e.g., at least one plastic and at least one rubber and / or elastomer) composed of materials having thermoplastic and elastomer properties.

[0103] Since one or both of the core 111 or sheath 112 may comprise a thermoplastic elastomer, the flexibility and elasticity of the core 111 or sheath 112 can be improved respectively, thereby improving the flexibility and elasticity of the molding material 1. Additionally, the desired production can be improved respectively.The flexibility and elasticity of the core or sheath provided in the molded product can thereby improve the flexibility and elasticity of the molded product to be produced.

[0104] In one or more embodiments, the thermoplastic elastomer may include any one, any combination or all of the following: olefin-based thermoplastic elastomers (TPO) (e.g., thermoplastic polyolefin elastomers); styrene-based thermoplastic elastomers (TPS) (e.g., styrene block copolymers); vinyl chloride thermoplastic elastomers (TPVC) (e.g., thermoplastic vulcanizates); amide-based thermoplastic elastomers (TPAE) (e.g., thermoplastic polyamides); ester-based thermoplastic elastomers (TPEE) (e.g., thermoplastic copolyesters); urethane-based thermoplastic elastomers (TPU) (e.g., thermoplastic polyurethanes); unclassified thermoplastic elastomers (TPZ); and acrylic elastomers, and may include TPU.

[0105] In one or more embodiments, the fiber / particle 123 may include one or both of natural and synthetic materials (e.g., compounds). Synthetic materials (e.g., synthetic fibers) may be chemically synthesized by humans, while natural materials (e.g., natural fibers, natural powders, mineral powders, etc.) may be derived directly from living organisms (e.g., plants (e.g., wool or cotton)). Various natural materials are considered. Examples of natural powders and fibers include ramie, cotton, wool, silk, chitosan, etc. Examples of mineral powders include chalk and calcium carbonate. Other examples are considered.

[0106] At least one of the core 111 and sheath 112 may include a reinforcing component. When the core 111 or sheath 112 includes a reinforcing component, one or more properties of the core 111 or sheath 112 (e.g., strength) may be improved, thereby affecting the formed material (e.g., increasing the strength of the formed material 1). Thus, in one or more embodiments, the reinforcing component may affect one or more properties, such as any one, any combination, or all of strength, hardness, stiffness, density, UV resistance, optical properties, or chemical resistance. In a specific example, the strength of the core or sheath provided in the molded product to be produced can be increased, thereby increasing the strength of the molded product to be produced. Various reinforcing components are considered. For example, reinforcing components may include fillers. In one or more embodiments, the filler includes any one, any combination, or all of the following: fibers; particles; particulate powder; nanoparticles; nanofibers; and similar additives. Furthermore, the filler may include, for example, one or both of natural and synthetic materials.

[0107] Furthermore, in one or more embodiments, one or both of the core 111 and sheath 112 may also include liquid additives in addition to plasticizers. Additionally or alternatively, one or both of the core 111 and sheath 112 may include additives for…Pore-forming additives. When the core 111 or sheath 112 contains additives for forming pores, a plurality of pores can be formed in the core or sheath provided in the molded product to be produced, thereby improving one or more of the flexibility, elasticity, and air permeability of the core and / or sheath provided in the molded product to be produced, and improving one or more of the flexibility, elasticity, and air permeability of the molded product to be produced. In one or more embodiments, the additives for forming pores may include one or both of, for example, a foaming agent or agitator. Filaments of foamed core / sheath structures (where the core or sheath is foamed while other layers are not foamed) can impart higher strength than filaments of fully foamed structures due to their high consistency with the strength of the unfoamed layers.

[0108] In one or more embodiments, the core 111 may include any, any combination, or all of particles, additives, mixtures, etc., which are not part of the above-described components. In one or more embodiments, any, any combination, or all of particles, additives, mixtures, etc., may be dispersed in a first thermoplastic polymer 121, which may constitute a matrix. Alternatively or additionally, the sheath 112 may include any, any combination, or all of particles, additives, mixtures, etc., that are not part of the aforementioned components. Furthermore, in one or more embodiments, any, any combination, or all of the particles, additives, or mixtures may be dispersed in a second thermoplastic polymer 122, which may constitute a matrix (e.g., may constitute the main polymer component in a material containing other components). In this respect, one or both of the first thermoplastic polymer 121 or the second thermoplastic polymer 122 may have any, any combination, or all of the particles, additives, or mixtures dispersed therein.

[0109] In a first example, the first thermoplastic polymer 121 is a TPU with a hardness of 70 Shore A. The second thermoplastic polymer 122 is also a TPU with a hardness of 60 Shore A. In this first example, the first thermoplastic polymer 121 has a greater hardness (e.g., greater indentation resistance) than the second thermoplastic polymer 122. In this respect, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may both be of the same type (e.g., TPU). In one embodiment, other aspects of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be the same (e.g., the same Shore A value) or may be different (e.g., different Shore A values). Specification 11 / 42 pages 15 CN 121100052 A

[0110] In the second example, the first thermoplastic polymer 121 is TPU. In addition, the second thermoplastic polymer 122 is PVA. In addition, the fiber / granules 123 are natural fibers. In this respect, the first thermoplastic polymer 121 and the second thermoplastic polymerMaterial 122 can be of different types (e.g., TPU and PVA).

[0111] In a third example, the first thermoplastic polymer 121 is TPU. Furthermore, the second thermoplastic polymer 122 is a mixture of TPU and PVA. Additionally, the sheath 112 contains a stirring (foaming) agent. In this respect, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may have at least one common material (e.g., TPU). In one or more embodiments, one or both of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may have additional materials not present in the other of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 (e.g., PVA present in the second thermoplastic polymer 122 but not in the first thermoplastic polymer 121).

[0112] In a fourth example, the second thermoplastic polymer 122 is TPU. Furthermore, the fiber / granule 123 is a natural fiber.

[0113] In the fifth example, both the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are TPU. Furthermore, the fiber / granule 123 is ramie fiber.

[0114] Consider various outer diameters (and corresponding ratios) of the sheath 112 and the core 111. The ratio of the outer diameter of the sheath 112 to the diameter of the core 111 can reflect the composition or mass fraction of the materials constituting the core 111 and the materials constituting the sheath 112, and can be controlled within a wide range of 1:1.01 to 1:10 (e.g., greater than 1:1 (e.g., 1:1.01); greater than 1:2 (e.g., 1:2.01); greater than 1:3 (e.g., 1:3.01); greater than 1:4 (e.g., 1:4.01); greater than 1:5 (e.g., 1:5.01); greater than 1:10 (e.g., 1:10.01); etc.).

[0115] 3. Method for Manufacturing the Molding Material The molding material 1 can be manufactured in one of a variety of ways. In one approach, the shaped material 1 can be manufactured by co-extruding the materials constituting the core 111 and the sheath 112 using appropriate feed heads and nozzles. In one or more embodiments, the same manufacturing method can be applied, for example, when the shaped material 1 comprises layers other than the core 111 and the sheath 112. Alternatively, different manufacturing methods can be used.

[0116] For example, in manufacturing the shaped material 1, the materials constituting the core 111 and the sheath 112 can be co-extruded in a co-extrusion line. In one or more embodiments, the co-extrusion line can include two extruders, a feed block / manifold die, and a nozzle. The two extruders can form two feeds, each comprising (or consisting of) a feed containing (or consisting of) the material constituting the core 111 and a feed containing (or consisting of) the material constituting the sheath 112. The feed block / manifold die can converge the two feeds formed. The nozzle can co-extrude the shaped material 1 by using the converged feed.

[0117] 4. Variation Figure 4 is a schematic cross-sectional view of the molding material of a variant of the first embodiment.

[0118] In the molding material 1 of the first embodiment shown in Figures 1, 2, and 3, the core 111 is a solid body. Alternatively, the core may be a non-solid body. For example, in the molding material 1M of the variant of the first embodiment shown in Figure 4, the core 111 is a porous body. Therefore, in the molding material 1M, a plurality of pores are formed within the core 111. This can improve any one, any combination, or all of the flexibility, elasticity, and air permeability of the core 111, thereby improving any one, any combination, or all of the flexibility, elasticity, and air permeability of the molding material 1M. Furthermore, any one, any combination, or all of the flexibility, elasticity, and air permeability of the core provided in the molded product to be produced can be improved, and any one, any combination, or all of the flexibility, elasticity, and air permeability of the molded product to be produced can be improved. In one or more embodiments, the core 111 may be a porous body, which may be similar to multifilament.

[0119] Second Embodiment 1. Molded Product Overview Figure 5 is a top view schematically representing a molded product of the second embodiment. The molded product 2 of the second embodiment shown in Figure 5 can be manufactured using the molding material 1 described in the specification of the first embodiment, page 12 / 42, 16 CN 121100052 A. Therefore, the molded product 2 can be a melt and / or solidified product of the molding material 1. Alternatively, any other molding material disclosed herein can be used to manufacture the molded product. As shown, the molded product 2 can be composed of multiple layers (e.g., at least two layers, at least three layers, at least four layers, at least five layers, at least six layers, at least seven layers, at least eight layers, at least nine layers, or at least ten layers).

[0120] In one or more embodiments, the molded product 2 can be a novel textile (e.g., fabric) or woven fabric (e.g., cloth article). The molded product 2 can, for example, constitute clothing that can be continuously worn on the body. Consider various garments, such as outerwear, hats, gloves, socks, footwear, accessories, etc. Alternatively, the molded product 2 can also constitute articles other than clothing.

[0121] The molded product, whether clothing or other articles, can be a homemade product made by a consumer, a product customized for a specific consumer, or a finished product manufactured for an unspecified consumer. However, manufacturing the molded product 2 using a 3D printer may be suitable for homemade and / or customized products.

[0122] The molded product 2 can be sold to ordinary consumers in ordinary stores and markets.

[0123] In one or more embodiments, the main body of the molded product 2 is thermoplastic. Therefore, the molded product 2 can be melted and separated into multiple parts. Furthermore, new molded products or other types of products can be manufactured from the molded product 2. Therefore, the molded product 2 can be recycled after use.

[0124] The properties of the molded product 2 can be adjusted by any one, any combination, or all of the following: the material constituting the molding material 1 used for manufacturing; the structure of the molding material 1 used for manufacturing; the process parameters used for manufacturing the molded product 2, etc. Various structures of the molded product are considered to meet specific design and functional requirements, including any one, any combination, or all of the following: solid; hollow; honeycomb filling; spiral filling; grid filling; triangular filling; sparse filling; concentric filling; linear filling; support structure; or textured surface. Furthermore, various process parameters, separate from but combined with different structures, can be adjusted or selected to control the quality and / or characteristics of the printed object, such as any one, any combination, or all of the following: layer height (e.g., not less than 0.05 mm and / or not more than 0.8 mm; at least 0.1 mm and / or 0.6 mm; e.g., 0.15 mm–0.25 mm; or 0.2 mm); number of layers (e.g., at least 2 layers; at least 5 layers; etc.); printing speed (e.g., not less than 4 mm / s and / or not more than 120 mm / s; at least 150 mm / s; at least 160 mm / s; at least 200 mm / s; at least 300 mm / s); nozzle temperature (e.g., not less than 190°C and / or not more than 260°C, depending on the filament material); bed temperature (e.g., not less than 25°C and / or not more than 100°C). ℃); fill density (e.g., not less than 5% and / or not more than 100%); and wall thickness (e.g., not less than 0.4 mm and / or not more than 1.2 mm). It is envisioned that adjustments can be made to improve any, any combination or all of the flexibility, softness, strength and breathability of the molded product 2, as well as the ease of manufacture of the molded product 2.

[0125] 2. The planar shape of the molded product is shown in FIG5. In one or some embodiments, the molded product 2 includes a first linear body 201 and a second linear body 202.

[0126] Each first linear body 201 extends meanderingly in a first direction D1. The first linear bodies 201 are arranged along a second direction D2. FIG5 shows an example lattice structure. Other lattice structures are considered only as examples, including serrated, inverted serrated, wavy fill, linen or wide wavy (with vertical or horizontal lines in the middle). There is a gap 203 between adjacent first linear bodies 201. Each second linear body 202 extends meanderingly in the second direction D2. The second linear bodies 202 are arranged along the first direction D1. A gap 204 exists between adjacent second linear bodies 202. In one or more embodiments, the gap 203 between adjacent first linear bodies 201 is the same as the gap 204 between adjacent second linear bodies 202. Alternatively, the gap 203 between adjacent first linear bodies 201 may be different from the gap 204 between adjacent second linear bodies 202. In this respect, the characteristics of the molded product 2...(For example, its thickness and / or profile) may vary depending on various aspects of the 3D printer (e.g., the printing nozzle of the 3D printer). Therefore, the formed product 2 can be modified to reflect design freedom. Specification 13 / 42 pages 17 CN 121100052 A

[0127] In one or more embodiments, the second direction D2 is perpendicular to the first direction D1. Alternative directions to the perpendicular direction are contemplated, including parallel or predetermined angles other than 90°. Thus, in a top view, the first linear body 201 intersects the second linear body 202. In addition, the formed product 2 has a lattice-like planar shape. Alternatively, the formed product 2 may also have a structure different from that shown in FIG. 5.

[0128] In one or more embodiments, the second linear body 202 may be arranged on the first linear body 201 in one of a variety of ways. On the one hand, the 3D printer can build the object layer by layer by extruding filaments through heated nozzles, depositing and curing a thin horizontal profile of material at a time, thereby constructing the formed product 2 shown in FIG. 5. Alternatively, instead of 3D printing, different filaments can be placed on top of each other or woven together, and then heated to bond the various filaments together. In either case, the second linear body 202 and the first linear body 201 are bonded together.

[0129] 3. Cross-sectional structure and material properties of the linear body FIG6 is a cross-sectional view schematically showing an example of a linear body provided in a molded product of the second embodiment. In FIG6, the molding material is indicated by dashed lines so that the dimensions of the molding material of the first embodiment can be compared with the dimensions of the linear body provided in the molded product of the second embodiment. In this regard, various dimensions of the molding material are considered.

[0130] In one or more embodiments, the linear body 210 shown in FIG6 may be a plurality of first linear bodies 201 and a plurality of second linear bodies 202 (as shown in FIG5). Therefore, in one or more embodiments, any discussion of the linear body 210 may include the first linear body 201 and the plurality of second linear bodies 202.

[0131] In one or more embodiments, the linear body 210 may be composed of a core (without a sheath). Alternatively, the linear body 210 may also be composed of a sheath. In this regard, the linear body 210 can be formed by extending the molding material 1 along its length. As shown in FIG6, the linear body 210 is composed of a core / sheath structure 221, which includes a core 231 and a sheath 232. In one or more embodiments, the diameter of the linear body 210 is smaller than the diameter of the molding material 1. Alternatively or additionally, the diameter of the core 231 may be smaller than the diameter of the core 111. Or, additionally, the thickness of the sheath 232 is thinner than the thickness of the sheath 112.

[0132] In one or more embodiments, the core 231 and sheath 232 provided in the linear body 210 are respectively derived from the molding material.The core 231 and sheath 112 are provided in material 1. Therefore, the core 231 can have a linear shape. The sheath 232 can cover at least a portion of the outer peripheral surface 231S of the core 231 (e.g., completely cover the outer peripheral surface 231S of the core 231). Alternatively, the sheath 232 may cover at least some (but not all) of the entire peripheral surface 231S (e.g., the sheath 232 may cover at least or more than 50% of the entire peripheral surface 231S; the sheath 232 may cover at least 60% of the entire peripheral surface 231S; the sheath 232 may cover at least 70% of the entire peripheral surface 231S; the sheath 232 may cover at least 75% of the entire peripheral surface 231S; the sheath 232 may cover at least 80% of the entire peripheral surface 231S; the sheath 232 may cover at least 85% of the entire peripheral surface 231S; the sheath 232 may cover at least 90% of the entire peripheral surface 231S; the sheath 232 may cover at least 95% of the entire peripheral surface 231S; the sheath 232 may cover at least 96% of the entire peripheral surface 231S; the sheath 232 may cover at least 97% of the entire peripheral surface 231S; the sheath 232 may cover the entire peripheral surface 231S). At least 98%; the sheath 232 may cover at least 99% of the entire peripheral surface 231S).

[0133] In one or more embodiments, the core 231 comprises a first thermoplastic polymer 121. In one or more embodiments, the sheath 232 comprises a second thermoplastic polymer 122 and fibers / particles 123. As described above, in one or more embodiments, the first thermoplastic polymer 121 may be the same as the second thermoplastic polymer 122. Alternatively, the first thermoplastic polymer 121 may be at least partially different from the second thermoplastic polymer 122. In one or more embodiments, the fibers / particles 123 may be dispersed in the second thermoplastic polymer 122. As an example, the fibers / particles 123 may be dispersed in the second thermoplastic polymer 122 by mixing the fibers / particles 123 with the second thermoplastic polymer 122 using a twin-screw compounding or similar melt mixing process. In one or more embodiments, the core 231 and sheath 232 provided in the linear body 210 may respectively comprise the components that may be contained in the core 111 and sheath 112 provided in the molding material 1. The core 231 may be a porous body. Specification 14 / 42 pages 18 CN 121100052 A

[0134] Furthermore, in one or more embodiments, the sheath 112 completely covers the core 111 (e.g., as shown in FIG. 6). Alternatively, the sheath 112 may cover at least some (but not all) of the entire outer peripheral surface of the core 111 (e.g., at least 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, or 99% of the outer peripheral surface of the core 111).

[0135] FIG. 7 is an electron microscope image of a cross-section of the linear body provided in the molded product prototype of the second embodiment.(SEM) photographs. Figure 8 is a SEM micrograph of the cross-sectional periphery of the linear body provided in the prototype of the molded product of the second embodiment.

[0136] In the SEM micrograph of Figure 7, a clear interface between the core 231 and the sheath 232 cannot be identified, but the fibers / particles 123 are almost invisible in the region of the core 231, while dispersed fibers / particles 123 can be identified in the region of the sheath 232 in front of arrow 233. In addition, in the SEM micrograph of Figure 8, a clear interface between the core 231 and the sheath 232 cannot be identified, but the fibers / particles 123 are almost invisible in the region of the core 231, while dispersed fibers / particles 123 can be identified in the circular inner region of the sheath 232. Therefore, it can be understood from the SEM micrographs of Figures 7 and 8 that the sheath 232 includes fibers / particles 123, and the fibers / particles 123 are dispersed in the second thermoplastic polymer 122. The reason why a clear interface between the core 231 and the sheath 232 cannot be confirmed is that the second thermoplastic polymer 122, which is a major component of the sheath 232, is similar to, and may be the same as, the first thermoplastic polymer 121, which can be a major component of the core 231.

[0137] FIG9 is an enlarged cross-sectional view schematically showing the interface between the molded product of the second embodiment and human skin in contact with the molded product. As shown in FIG9, the linear body 210 includes a linear body 241 and a protrusion 242.

[0138] The linear body 241 constitutes the main part of the linear body 210. The protrusion 242 protrudes from the outer peripheral surface 241S of the linear body 241 to form a characteristic irregularity and non-uniformity on the outer peripheral surface of the linear body 210. In one or more embodiments, in filament form, the particles are generally uniformly dispersed within a matrix (e.g., a polymer); however, the dispersion may depend on any, any combination of, or all of the following aspects: particle type (e.g., chemical structure); particle length; dispersion level; mixing strength; compatibility between the particles and the polymer; etc. Nevertheless, the dispersion of the particles within the matrix can be predetermined to a sufficient degree by appropriately controlling one or more of the listed aspects.

[0139] In one or more embodiments, the fiber / particle 123 comprises cross-fibers / cross-particles 251 intersecting with the outer peripheral surface 241S of the linear body 241. One end of the cross-fibers / cross-particles 251 is embedded in a second thermoplastic polymer 122 constituting the linear body 241. Thus, the cross-fibers / cross-particles 251 are fixed to the linear body 241 and can be prevented from detaching from the linear body 241. The remaining or residual cross-fibers / cross-particles 251 protrude from the outer peripheral surface 241S of the linear body 241 and are covered by the second thermoplastic polymer 122 constituting the protrusion 242. Therefore, it can preventTo prevent the cross-fibers / cross-particles 251 from being exposed, direct contact between human skin 261 and the cross-fibers / cross-particles 251 may be prevented. The protrusion 242 includes a second thermoplastic polymer 122 covering the remaining cross-fibers / cross-particles 251 and the remaining cross-fibers / cross-particles 251. The second thermoplastic polymer 122 constituting the linear body 241 is continuous and integrally formed with the second thermoplastic polymer 122 constituting the protrusion 242. Alternatively, in one or more embodiments, the cross-fibers / cross-particles 251 may be located within the sheath (e.g., outside the outer surface of the core) and are not covered by the second thermoplastic polymer 122 due to the cross-fibers / cross-particles 251 protruding from the core (e.g., the cross-fibers / cross-particles 251 were initially added to the core and through processing, such as by applying force, such as electrostatic charge, discussed further below).

[0140] The resulting irregularity and inhomogeneity are similar to the inhomogeneity formed when the fill factor of the fibers / particles dispersed in the matrix increases. This inhomogeneity can be described as “mountains and valleys” or “peaks and valleys”. In the linear body 210, the protrusions 242 can be considered as mountains (e.g., peaks), and the areas between adjacent protrusions 242, i.e., regions rich in the second thermoplastic polymer 122, can be considered as valleys. Specification 15 / 42 pages 19 CN 121100052 A

[0141] The size of the irregularities and inhomogeneities formed can be controlled by the shape, size, etc. of the fibers / particles 123. Therefore, the surface roughness of the molded product 2 can be controlled by the shape, size, etc. of the fibers / particles 123. For example, in one or more embodiments, one or more processing parameters and / or settings of the 3D printer may also affect the roughness (e.g., peaks and valleys).

[0142] When human skin 261 comes into contact with the molded product 2, human skin 261 comes into contact with the protrusions 242, and a gap 262 is formed between human skin 261 and the outer peripheral surface 241S of the linear body 241. An airflow can be generated in the formed gap 262. Therefore, when human skin 261 comes into contact with the molded product 2, the airflow generated in the gap 262 can quickly dry the human skin 261 and cool it well. Therefore, the molded product 2 will not have a rubbery or plastic-like feel, but can have a cloth-like feel and a comfortable feel.

[0143] In addition, when human skin 261 comes into contact with the molded product 2, the human skin 261 can deflect the protrusion 242 with a relatively weak force. Furthermore, the human skin 261 can only have weak contact with the surface of the molded product 2, and the frictional force generated between the human skin 261 and the molded product 2 can be relatively small. Thus, the molded product 2 can have a soft feel.

[0144] Figures 10 and 11 are SEM micrographs of cross-sections of the prototype of the molded product according to the second embodiment. In Figures 10 and 11...In the SEM micrograph of Figure 11, protrusion 242 is shown to protrude from the sheath 112, forming irregular non-uniformities on the outer peripheral surface of the linear body 210.

[0145] Figures 12 and 13 are SEM micrographs of cross-sections of a prototype of a molded product made using monofilament. Figures 14 and 15 are SEM micrographs of the upper surface of a prototype of a molded product made using monofilament.

[0146] In the SEM micrographs of Figures 12, 13, 14, and 15, the surface of the linear body provided in the prototype of the molded product made using monofilament is shown to be smooth and clean, without obvious non-uniformities. In the SEM micrographs of Figures 14 and 15, white spots can be considered as debris or contaminants.

[0147] The molded product 2 having the above characteristics may have any one, any combination, or all of the following: flexibility, strength, breathability, wicking, controlled roughness, and smoothness, and may have a fabric-like and comfortable feel. In addition, the color of the molded product 2 may be changed.

[0148] FIG16 is an SEM micrograph of a prototype of a molded product manufactured using a molding material of a variant of the first embodiment. FIG17 is a micrograph of a monofilament made of polyester. FIG18 is a micrograph of a multifilament made of polyester.

[0149] The monofilament made of polyester shown in FIG17 is strong and rigid. Therefore, the monofilament made of polyester may not be considered suitable for clothing. In addition, when using monofilament, irregular non-uniformity cannot be formed on the surface of the molded product.

[0150] On the other hand, the multifilament made of polyester shown in FIG18 is softer and less rigid than monofilament. Therefore, the multifilament made of polyester may be considered suitable for clothing. In addition, when using multifilament, irregular non-uniformity may be formed on the surface of the molded product. However, when using monofilament made of polyester, the molded product cannot be printed by a 3D printer.

[0151] In the SEM micrograph of FIG16, it can be confirmed that the surface of the molded product manufactured by a 3D printer using molding material 1M has irregular non-uniformity, wherein the core 111 is a porous body.

[0152] 4. Method for Manufacturing a Molded Product Figure 19 is a schematic side view of a 3D printer 271 for manufacturing a molded product according to a second embodiment. The 3D printer 271 shown in Figure 19 uses a molding material 1 to print a molded product 2 using one or more methods such as the FFF method. Hereinafter, the molding material 1 may include filaments. For this purpose, any discussion of filaments below generally applies to any molding material 1.

[0153] A filament spool 281 is mounted on the 3D printer 271. The 3D printer 271 includes a print head 282, a drive mechanism 283, and a plate 284. The 3D printer 271 may also include control electronics 285, which can communicate with the printer via wired and / or wireless means. (See page 16 / 42 of the specification, 20 CN 121100052 A)The printhead 282, drive mechanism 283, and plate 284 communicate with each other, in any combination, or in all of them (see 289). Figure 42 further discusses an example of control electronics 285.

[0154] Control electronics 285 can be configured to control various parts of the 3D printer 271 to perform 3D printing as discussed herein. Control electronics 285 may include at least one processor 286 (e.g., CPU 4202 in Figure 42) and at least one memory 287 (e.g., one or both of RAM 4206 or ROM 4208). In one or more embodiments, processor 286 may include a microprocessor, controller, PLA, etc. Similarly, memory 287 may include any type of storage device (e.g., any type of memory). Memory 287 may be a tangible, non-transient, computer-readable storage medium that stores software that may include instructions. These instructions may be executed by processor 286 (which operates as part of a computer, see Figure 42) to perform 3D printing as discussed herein.

[0155] Although processor 286 and memory 287 are depicted as separate elements, they may be part of a single machine that includes a microprocessor (or other type of controller) and memory. Alternatively, processor 286 may rely on memory 287 to meet all its memory needs.

[0156] Processor 286 and memory 287 are merely one example of control electronics 285. Consider other types of control electronics. For example, all or part of the scheme may be a circuit that includes a controller, including an instruction processor, such as a central processing unit (CPU), microcontroller, or microprocessor; or as an application-specific integrated circuit (ASIC), programmable logic device (PED), or field-programmable gate array (FPGA); or as a circuit that includes discrete logic or other circuit components, including analog circuit components, digital circuit components, or both; or any combination thereof. For example, the circuit may include discrete interconnect hardware components, or may be implemented in a multi-die module (MCM) of multiple integrated circuit dies, distributed across multiple integrated circuit dies, or in a common package.

[0157] A filament spool 281 supplies filaments. In one or more embodiments, the printhead 282, under the control of the control electronics 285, can melt the supplied filament to generate molten material, and can discharge the generated molten material 288. The printhead 282 may be vertically positioned above the upper surface 284S of the plate 284. Therefore, the discharged molten material 288 can drip and be supplied onto the upper surface 284S of the plate 284. The molten material 288 can be supplied directly onto the upper surface 284S of the plate 284, or it can be supplied by overlapping molten material already supplied to the upper surface 284S of the plate 284 or by hardening molten material.The molten material 288 is fed onto the upper surface 284S of the plate 284.

[0158] In one or more embodiments, the drive mechanism 283 may include one or more motors and, under the control of the control electronics 285, may move the print head 282 in a direction parallel to the upper surface 284S of the plate 284 (e.g., the control electronics 285 may send one or more commands to the motor 294 of the drive mechanism 283 to move the print head 282). This allows the position of the supplied molten material 288 to be moved. The drive mechanism 283 is capable of configuring the supply position of the molten material 288 at any position within the printing range.

[0159] The plate 284 may support the supplied molten material 288. The supported molten material 288 may harden into a molten and solidified product. Therefore, the plate 284 supports the molten and solidified material.

[0160] Under the control of the control electronics 285, when the 3D printer 271 prints the formed product 2, while the print head 282 discharges molten material 288, the drive mechanism 283 can move the print head 282 above the linear region printed by the linear body 210 provided in the formed product 2. Thus, linear molten material can be formed on the linear region. The formed linear molten material can be hardened into the linear body 210.

[0161] The print head 282 may include a filament feeder 291, a heater 292, and a nozzle 293. Under the control of the control electronics 285, the filament supplied to the print head 282 can be inserted into the filament feeder 291. The filament feeder 291 can feed the inserted filament along its length and can insert the filament into the heater 292. Specification page 17 / 42 21 CN 121100052 A

[0162] In one or more embodiments, under the control of control electronics 285, heater 292 can heat the inserted forming material 1 (e.g., filament) to generate molten material 288, and can supply the generated molten material 288 to nozzle 293. Nozzle 293 can discharge the supplied molten material 288.

[0163] When printhead 282 melts filament to generate molten material 288, the core / sheath structure can be maintained. Therefore, linear body 210 can have core / sheath structure 221. However, in one or more embodiments, the diameter of linear body 210 may be smaller than the diameter of filament because filament is stretched. In addition, in one or more embodiments, the thickness of sheath 232 may be thinner than the thickness of sheath 112. For example, the diameter of linear body 210 is about 1 / 4 of the diameter of filament. In this regard, in one or more embodiments, the diameter of the filament is: at least twice the diameter of the linear body 210; at least three times the diameter of the linear body 210; at least four times the diameter of the linear body 210; at least five times the diameter of the linear body 210; at least six times the diameter of the linear body 210; etc. Additionally, the sheath 232...The thickness is approximately 1 / 4 of the thickness of the sheath 112. In this regard, in one or more embodiments, the thickness of the sheath 112 is: at least twice the thickness of the sheath 232; at least three times the thickness of the sheath 232; at least four times the thickness of the sheath 232; at least five times the thickness of the sheath 232; at least six times the thickness of the sheath 232; etc. Thus, in one case, a filament with a diameter of 1.75 mm becomes a linear body 210 with a diameter of approximately 0.40 mm. A sheath 112 with a thickness of 0.2 mm becomes a sheath 232 with a thickness of 0.05 mm.

[0164] The size of the fiber / particle 123 contained in the sheath 112 provided in the filament, such as the length of the fiber or the size of the particle, is selected to be sufficiently smaller than the thickness of the sheath 232 provided in the linear body 210 to be printed. Therefore, when printing the formed product 2, the fiber / particle 123 is unlikely to enter the core 231. Therefore, most of the fibers / particles 123 will remain inside the sheath 232, and a portion of the fibers / particles 123 will become cross fibers / particles 251 that intersect with the outer peripheral surface 111S of the linear body 241.

[0165] Third Embodiment 1. Overview of Flocked Product Figure 20 is a top view schematically showing the flocked product of the third embodiment. Figure 21 is an enlarged cross-sectional view schematically showing the interface between the flocked product of the third embodiment and the human skin in contact with the flocked product.

[0166] The flocked product 3 of the third embodiment shown in Figures 20 and 21 is a molded product made using a molding material. The flocked product 3 is a novel textile or fabric. The flocked product 3 can constitute, for example, clothing that can be continuously worn on the body. Consider various garments, such as outerwear, hats, gloves, socks, footwear, accessories, etc. Alternatively, the flocked product 3 can also constitute articles other than clothing.

[0167] The molded product, whether it is clothing or articles other than clothing, can be a self-made product made by a consumer, a customized product made for a specific consumer, or a finished product made for an unspecified consumer. However, manufacturing shaped products using a 3D printer and manufacturing flocked products 3 using flocking may be suitable for homemade and / or customized products.

[0168] The properties of flocked product 3 may include thermoplasticity.

[0169] 2. The structure of the flocked product is shown in Figures 20 and 21. The flocked product 3 includes a body 301, an adhesive layer 302, and flocking 303. The body 301 may be a shaped product made using a molding material, or a product of melting and solidifying the molding material. The molding material may be a molding material having a single-layer structure, may be molding material 1 of the first embodiment having a multi-layer structure, or may be another molding material, but may contain a thermoplastic polymer. In one or more embodiments, the body 301 may be manufactured by a 3D printer. Alternatively, the body 301 may also be manufactured by a machine other than a 3D printer. The body 301 may be the molding material itself.

[0170] Adhesive layer 302 may be disposed on and cover surface 301S of body 301. Adhesive layer 302 may bond flock 303 to surface 301S of body 301 and may fix flock 303 to surface 301S of body 301. Various types of adhesion are considered. In one or some embodiments, heat may be used for curing. Alternatively, curing / drying may be performed at room temperature. In one or some embodiments, the type and / or time of curing may depend on the type of adhesive used.

[0171] In one or some embodiments, flock 303 may be bonded to adhesive layer 302 in one of a variety of ways. In one or some embodiments, flock 303 may puncture adhesive layer 302. Alternatively, flock 303 may bond to adhesive layer 302 without puncturing (but only by contact).

[0172] Therefore, in one or some embodiments, puncture may occur when an external force is applied. Various types of force are considered. For example, the applied force may include a strong electrostatic force generated during the process of charged fibers exerting a strong attraction on a grounded substrate due to opposite charges. Upon reaching the adhesive, the fibers may embed themselves (e.g., puncture) due to the combined force of the electrostatic force and the adhesive. Thus, in one or more embodiments, the result may include a dense, soft stack of fibers standing upright on the substrate or perpendicular to the surface. One end of the flocking 303 may be embedded in the adhesive layer 302. The remaining flocking 303 may be arranged or positioned outside the adhesive layer 302. Thus, in one or more embodiments, the flocking 303 may protrude from the adhesive layer 302.

[0173] As shown in FIG21, when human skin 311 contacts the flocked product 3, the human skin 311 contacts the flocking 303, and a gap 321 is formed between the human skin 311 and the surface of the structure consisting of the body 301 and the adhesive layer 302. Airflow may be generated in the formed gap 321. Therefore, when human skin 311 comes into contact with flocked product 3, the airflow generated in gap 321 can quickly dry human skin 311 and effectively cool human skin 311. Therefore, flocked product 3 may not have a rubbery or plastic-like feel, but may have a cloth-like feel, providing a comfortable touch.

[0174] Furthermore, if human skin 311 comes into contact with flocked product 3, human skin 311 may deflect the flock 303 with a relatively weak force. Additionally, human skin 311 may only have weak contact with the surface of flocked product 3, and the frictional force generated between human skin 311 and flocked product 3 may be small. Thus, flocked product 3 may have a soft touch.

[0175] In one or more embodiments, body 301 comprises a thermoplastic polymer. In one or more embodiments...In this process, the thermoplastic polymer may be a thermoplastic polyurethane. The properties of the body 301 can be adjusted by the molding material used during manufacturing.

[0176] The adhesive layer 302 may include (or consist of) a curing adhesive. In one or more embodiments, the adhesive is adjusted to fit the body 301 and the flocking 303.

[0177] In one or more embodiments, the adhesive is a thermoplastic adhesive or a thermosetting adhesive. In this regard, in one or more embodiments, a thermosetting adhesive may be used alone as the adhesive. If the adhesive is a thermosetting adhesive, the durability of the adhesive layer 302 can be improved. On the other hand, if the adhesive is a thermoplastic adhesive, electrostatic deposition of the flocking 303 can be easily performed.

[0178] In one or more embodiments, the adhesive is a polymeric adhesive, such as a polyurethane adhesive or an acrylic adhesive, and more specifically, only a polyurethane adhesive. If the adhesive is a polyurethane adhesive, the adhesive layer 302 contains a flexible polyurethane, which can prevent the adhesive layer 302 from compromising the flexibility of the flocked product 3. The polyurethane adhesive may be, for example, a water-based or solvent-based polyurethane dispersion or a liquid polyurethane.

[0179] In one or more embodiments, flocking 303 comprises one or both of fibers and particles. Flocking 303 may comprise one or both of natural materials and synthetic materials (e.g., compounds). Natural materials may comprise any one, any combination of, or all of cotton, wool, and viscose. Alternatively, natural materials may comprise substances other than cotton, wool, and viscose. Compounds may comprise any one, any combination of, or all of the following: polyester; polyamide (e.g., nylon); polyurethane; polylactic acid (PLA); polyethylene; and polypropylene. Alternatively, compounds may comprise substances other than polyester, polyamide, polyurethane, polylactic acid, polyethylene, and polypropylene. Specification 19 / 42 pages 23 CN 121100052 A

[0180] For example, the length of the flocking fibers may be 0.1 mm or greater and 5 mm or less, for example, at least 0.4 mm or greater and at most 8 mm or less. If the length of the flocking fibers is shorter than these ranges, the flocking fibers may be embedded in the polymer, may not protrude from the surface, and may not affect the tactile feel of the surface. Additionally, if the protruding portion of the flocked fiber is too short, the fiber will stand upright and may produce an itchy feel. If the fiber length is longer than these ranges, the fiber deposition may be insufficient during the flocking process due to the fiber's weight. If the flocked fiber is too long, the fiber may fall off, thus risking a loss of fluffy feel.

[0181] For example, the diameter of the flocked fiber can be from at least 1 μm to over 100 μm. If the fiber diameter is smaller than this range, generally, a large amount of dust can be generated at the manufacturing site, and when the dust enters the lungs, there may be a risk of lung disease. For productionFor the end user of the product, flocked fibers may adhere to the surface of the printed fabric, thus presenting a similar problem. If the diameter of the flocked fibers is larger than this range, it may be difficult to flock the fibers (e.g., embed or disperse them) in the polymer because the fibers may not fit the thickness of the sheath. Additionally, if the fiber diameter is too large, it may produce a stiff feel, potentially losing softness and deteriorating the tactile sensation.

[0182] In the first example, the body 301 may be made of monofilaments made of TPU. The adhesive may be a polyurethane adhesive. The flock 303 may be cotton fibers. Thus, the body 300 can become soft, and the surface feel of the flocked product 3 can become a comfortable feel, thereby the flocked product 3 can be formed into a comfortable garment.

[0183] In the second example, the body 301 may be made by using a core / sheath (e.g., the sheath comprises fibers and / or particles). The adhesive may be a polyurethane adhesive. In one example, the flock 303 may be cotton fibers. In one embodiment, the flock 303 may have the same material type as the fibers and / or particles in the sheath (e.g., both are cotton). Alternatively, flocking 303 may have a material of a different type than the fibers and / or particles in the sheath (e.g., one is a natural fiber (e.g., flocking 303), and the other is a synthetic fiber). Due to the combination of flocking and the sheath, the body 300 can be both soft and give the surface of the flocked product 3 a multi-layered tactile feel, thus allowing the flocked product 3 to be formed into a comfortable garment.

[0184] As shown in Figures 20 and 21, the flocked product 3 includes a first linear body 331 and a second linear body 332. Therefore, in one or more embodiments, the depiction in Figure 20 is similar to the depiction in Figure 5. Therefore, in one or more embodiments, any discussion regarding Figure 5 applies to the description in Figure 20. As an example, any discussion regarding the first linear body 201 and the second linear body 202 can apply to the first linear body 331 and the second linear body 332, respectively. Each first linear body 331 may meander along a first direction D1. The first linear bodies 331 may be arranged along a second direction D2. A gap 333 may exist between adjacent first linear bodies 331. Each second linear body 332 extends meanderingly along the second direction D2. The second linear bodies 332 are arranged along the first direction D1. A gap 334 may exist between adjacent second linear bodies 332. In one or some embodiments, the second direction D2 is perpendicular to the first direction D1. Alternatively, the second direction D2 is not perpendicular to the first direction D1. Thus, in a top view, the first linear body 331 intersects with the second linear body 332. The flocked product 3 also has a grid-like planar shape.

[0185] In one or some embodiments, the second linear body 332 is disposed on the first linear body 331. More specifically, the second linear body 332 may contact or touch the first linear body 331. Similar to the discussion above, the first linear body 331 and the second linear body 332...The bonding of bodies 332 can be performed in one of a variety of ways, including using heat (e.g., placing molten thermoplastic material on top of a previously deposited layer), building the object layer by layer, or 3D printing by weaving the first linear body 331 and the second linear body 332 together in a sequential layering manner.

[0186] The flocked product 3 having the above-described characteristics can have any one, any combination or all of the following: softness, comfort, breathability, wicking effect, controlled roughness and smoothness; or have a fabric-like feel and a comfortable feel. That is, flocking can turn a 3D-printed product into a real wearable textile or fabric. In addition, the color of the flocked product 3 can be changed. Specification 20 / 42 pages 24 CN 121100052 A

[0187] 3. Method for manufacturing flocked products FIG22 is a perspective view schematically showing a device that can generate applied force, such as an electrostatic deposition device used in the manufacturing of flocked products in the third embodiment. The electrostatic deposition apparatus 341 shown in FIG22 may include an upward electrostatic deposition apparatus that can pull the flocked 303 in a predetermined direction (e.g., vertically upward). Alternatively, the electrostatic deposition apparatus can pull the flocked 303 in various other directions, such as downward, lateral, etc. In this respect, the electrostatic deposition apparatus 341 may be an electrostatic deposition apparatus other than an upward electrostatic deposition apparatus. For example, the electrostatic deposition apparatus 341 may be a downward electrostatic deposition apparatus that deposits the flocked 303 vertically downward, etc.

[0188] As shown in FIG22, the electrostatic deposition apparatus 341 may include a first electrode 351, a second electrode 352, a chamber 353, and a power supply 354. In one or some embodiments, the first electrode 351 has a flat plate shape. Further, in one or some embodiments, the first electrode 351 is horizontally mounted.

[0189] In one or some embodiments, the second electrode 352 has a flat grid shape. In addition, in one or some embodiments, the second electrode 352 is arranged relative to the first electrode 351, for example, above the first electrode 351 in a vertical direction. In one or more embodiments, the second electrode 352 is mounted horizontally. Therefore, the second electrode 352 may be parallel to the first electrode 351. In one or more embodiments, the second electrode 352 is grounded. In one or more embodiments, a chamber 353 may accommodate the first electrode 351 and the second electrode 352.

[0190] In one or more embodiments, a power supply 354 generates a high DC voltage. The positive electrode 361 of the power supply 354 may be electrically connected to the first electrode 351. The negative electrode 362 of the power supply 354 may be electrically connected and grounded to the second electrode 352. Thus, the generated high DC voltage can be applied between the first electrode 351 and the second electrode 352. Other electrical connections between the positive electrode 361 and the negative electrode 362 are also considered.

[0191] When flocking 303 is electrostatically deposited on workpiece 371, flocking 303 can be placed on the upper surface 351S of the first electrode 351. Additionally, workpiece 371 can be mounted above the second electrode 352. Subsequently, power supply 354 can apply a high DC voltage between the first electrode 351 and the second electrode 352. As a result, flocking 303 becomes charged, and due to the applied voltage, the charged flocking 303 can move or fly from the upper surface 351S of the first electrode 351 to the workpiece 371 via the second electrode 352. At this time, the charged flocking 303 can pass through the gap formed in the second electrode 352. The flocking 303 reaching workpiece 371 can adhere to workpiece 371. Thus, flocking 303 can be electrostatically deposited on workpiece 371.

[0192] FIG23 is a flowchart showing the manufacturing process of the flocked product according to the third embodiment. When manufacturing the flocked product 3, any one, any combination, or all of steps S101 to S106 shown in FIG23 can be performed. Step S101 may include a primary process of printing the body 301 using a 3D printer. Steps S102 to S105 following step S101 may include secondary processes of altering the tactile feel and / or appearance of the surface of the body 301 by electrostatic deposition (e.g., electrostatic flocking) performed on the surface of the printed body 301. In this regard, in one or more embodiments, the fabrication of the flocked product may be accomplished through a series of processes, including the primary process of printing the body and secondary processes (e.g., by electrostatic deposition) that modify the tactile feel and / or appearance of the surface of the body 301.

[0193] In step S101, the body 301 to be processed may be fabricated. In one or more embodiments, the body 301 may be fabricated by a 3D printer and by an FFF method. Alternatively, the body 301 may also be fabricated by a forming apparatus other than a 3D printer or by a forming method other than an FFF method.

[0194] In the subsequent step S102, an adhesive layer 302 may be arranged or positioned on the surface 301S of the body 301. Thus, a workpiece 371 made of the body 301 and the adhesive layer 302 can be produced. In one or more embodiments, the liquid adhesive can be applied to the surface 301S of the body 301 by one or more methods such as spraying, brushing, rolling, or scraping. The application of the liquid adhesive can be performed in one of several ways. On the one hand, the application of the liquid adhesive can be performed in response to determining that the adhesive layer 302 is located on the surface 301S of the body 301. This determination can be based on one or more sensors, such as a camera, which can determine that the adhesive layer 302 is located on the surface 301S of the body 301 by analyzing one or more images of the adhesive layer 302 and / or the surface 301S of the body 301 through the control electronics 285. In this regard, the control electronicsThe device 285 may be configured to perform image analysis (e.g., image segmentation and / or object recognition) on the one or more images to determine that the adhesive layer 302 is located on the surface 301S of the body 301. Alternatively or additionally, the control electronics 285 may control one or more motors 294 of the drive mechanism 283 to move the adhesive layer 302 and the surface 301S of the body 301 relative to each other (e.g., move the adhesive layer 302 to be arranged or positioned on the surface 301S of the body 301). The control electronics 285 may wait a predetermined time (without sensing that the adhesive layer 302 is actually arranged or positioned on the surface 301S of the body 301) before applying the adhesive.

[0195] In one or more embodiments, a thin adhesive layer 302 may be applied to at least a portion of the 301S of the body 301, for example, by applying a thin adhesive layer 302 such that it extends through at least a portion of the surface 301S of the body 301, for example, across the surface 301S of the body 301. In one or more embodiments, the adhesive to be applied may be selected to be suitable for or applicable to electrostatic deposition. The adhesive layer 302 can promote or assist the adhesion between the flocking 303 and the body 301.

[0196] In the next step S103, one or both of the flocking 303 and the workpiece 371 are introduced into the chamber 353. At this time, the flocking 303 can be placed on the upper surface 351S of the first electrode 351. Alternatively, the workpiece 371 can be arranged vertically above the second electrode 352. Alternatively, the flocking 303 and the workpiece 371 can be positioned relative to each other with different orientations.

[0197] In the next step S104, the flocking 303 can be inserted into the adhesive layer 302. In this way, the flocking 303 can penetrate the adhesive layer 302, thereby establishing a bond between the flocking 303 and the adhesive layer 302. In one or more embodiments, the flocking 303 is inserted into the adhesive layer 302 by electrostatic deposition. At this time, a high DC voltage can be applied between the first electrode 351 and the second electrode 352 by the power supply 354. This allows the flocking 303 to become charged, and the charged flocking 303 can fly or move from the upper surface 351S of the first electrode 351 to the workpiece 371 via the second electrode 352. The flocking 303 reaching the workpiece 371 may adhere to the adhesive layer 302. Thus, the flocking 303 can adhere to the surface 301S of the body 301 via the adhesive layer 302 and cover the surface 301S of the body 301. This can provide a new tactile feel. One end of the attached flocking 303 can be at least partially inserted into the adhesive layer, for example, embedded in the adhesive layer 302, and can be fixed to the adhesive layer 302. In one or more embodiments, the remaining portion or residual portion of the attached flocking 303 can be arranged or positioned outside the adhesive layer 302. Thus, the flocking 303 can at least partially...The flocking 303 protrudes from and is at least partially embedded within the adhesive layer 302. Therefore, the flocking 303 can penetrate the adhesive layer 302, and the flocking 303 protrudes from the adhesive layer 302. If the flocking 303 is fiber, it can penetrate the adhesive layer 302 in a state substantially perpendicular to the surface 301S of the body 301. In this way, the electrostatic field can force the flocking 303 to move upwards, thereby attaching it vertically to the surface. Especially with the flocking 303 penetrating vertically, the surface area can be significantly increased, thereby improving the density of the product and the final textile feel.

[0198] In the next step S105, the adhesive layer 302 can be cured. At least partially during curing (e.g., throughout the curing process), the adhesive layer 302 can be dried and baked by means of heating or the like.

[0199] In the next step S106, cleaning can be performed. At this time, excess flocking 303 that is not adhered to the body 301 can be removed from the adhesive layer 302. This completes the flocked product 3.

[0200] In one or more embodiments, flocking can be performed manually using a portable electrostatic spraying device or the like. Alternatively, flocking can be performed at least partially automatically. For example, any one, any combination, or all of steps S101, S102, S103, S104, S105, and S106 can be performed automatically.

[0201] FIG24 is a photograph of a prototype of the body provided in the flocked product of the third embodiment. FIG25 is a photograph of a prototype of the flocked product of the third embodiment. When comparing the body 301 before flocking shown in FIG24 and the flocked product 3 after flocking shown in FIG25, it can be understood that flocking can create complex non-uniformities on the surface of the flocked product 3.

[0202] Step S102, which places the adhesive layer 302 on the surface 301S of the body 301, and step S104, which inserts the flocking 303 into the adhesive layer 302, can take only a short time, for example, 3-10 minutes. If the steps are automated, even shorter times can be considered. In one or more embodiments, step S105, which cures the adhesive layer 302, takes a longer time, for example, several hours (e.g., at least one hour, which can be at least 2, at least 3, at least 5, at least 10, or at least 20 times longer than one or both of steps S102 or S104). However, by selecting the adhesive, the time required for step S105 can be reduced.

[0203] The coating state of the flocking 303 on the surface 301S of the body 301 can be adjusted by adjusting one or more parameters of the electrostatic deposition in step S104. For example, by adjusting any, any combination, or all of the voltage and / or current intensity of the electrostatic unit, the height between electrodes, the height of the substrate from the electrodes, or the flocking time (e.g., the time for applying current), the coating state can be adjusted.The flocked product 303 can be uniformly coated on the entire surface 301S of the body 301, or the surface 301S of the body 301 can be coated with flocked 303 to create a gradient in the density of the flocked 303.

[0204] The feel of the flocked product 3 can be adjusted by adjusting any, any combination, or all of the type, detex (dTex), or length of the flocked 303. Furthermore, various types of fibers can be flocked, including natural or synthetic fibers, including cotton, wool, polyester, polyamide, or rayon. In one or more embodiments, detex is a number representing the weight in grams of 10,000 meters of sewing thread. The density of the flocked 303 can be adjusted by adjusting the body 301, the properties of the adhesive, the characteristics of the flocked 303, and the process conditions.

[0205] In one or more embodiments, the flocked 303 may be less affected by one, some, or all of the materials of the body 301, but can be adjusted by selecting the adhesive. Thus, flocked products 3 suitable for a variety of applications can be manufactured. In this respect, the characteristics of the flocked product 3 are unlikely to be affected by the characteristics of the body 301 and can be adjusted by selecting the adhesive. This is likely because the adhesive layer 302 can act as an intermediate layer connecting the flocked 303 and the body 301, effectively isolating the flocked 303 from the body 301. In one or more embodiments, the flocking quality may be affected by any one, any combination, or all of the following: the body; the adhesive layer; the flocking type; or the flocking processing parameters.

[0206] In one or more embodiments, two or more types of flocked 303 can be combined to obtain a structure and characteristics of the flocked product 3 that may not be obtainable when using one type of flocked 303.

[0207] In one or more embodiments, in order to implement the above-described method of manufacturing the flocked product, a factory can be established to perform the above-described primary and secondary processes according to customer demand or seasonal collection. In particular, a factory can be established to perform only the above-described secondary processes according to customer demand. In this case, the body 300 can be provided by the customer.

[0208] Consider various fibers. Specifically, currently available modern fiber implementations include: (i) Monofilaments: These fibers are relatively stiff, so they may not be suitable for clothing. These fibers are generally not breathable, or have limited breathability. Any moisture (such as sweat) remains on the surface of clothing woven from monofilament fibers because these fibers do not have any moisture-wicking capacity. These properties of monofilament fibers may make them uncomfortable to wear when woven into clothing.

[0209] (ii) Multifilaments: Multifilament fibers have the property of providing a soft feel to clothing woven from such fibers. Multifilament fibers are considered to be more breathable than monofilament fibers and can allow more moisture to pass through any material woven using these fibers (compared to materials woven using monofilament fibers). This material may also have better moisture-wicking capacity (compared to materials woven using monofilaments).Compared to woven fiber materials, where moisture (e.g., sweat) may not remain on the surface and can be absorbed by the material.

[0210] Currently available TPU filaments are monofilament structures. These structures may be rigid and may not be suitable as candidate fibers for manufacturing wearable fabrics due to associated discomfort.

[0211] Aspects of the present invention may relate to the design and manufacture of filament structures (also referred to as “fibers”), referred to herein as “comfort fibers” or “comfort filaments”. These filament structures may also be referred to as “comfort filaments” or “comfort filaments”. Comfort fibers may inherently possess properties similar to moisture absorption, while being soft and comfortable for the wearer of outerwear made from these filaments. In one aspect, comfort fibers may include any one, any combination, or all of the desired characteristics of multifilament fibers. An example of a comfort fiber is molding material 1. In one aspect, a comfort fiber may consist of one or both of the following: (i) an outer layer (also referred to as a “sheath”). This layer may resemble a sheath 112. In one aspect, the sheath may include one or more natural powders and fibers (e.g., ramie, cotton, wool, silk, chitosan, etc.) that can add texture to the outer surface of the sheath. In another aspect, the sheath may include one or more natural powders blended with fibers (e.g., when manufacturing a sheath with a high aspect ratio). Generally, the sheath may include any one, any combination, or all of powders, natural fibers, and additives, combined in appropriate proportions to construct a comfort fiber with one or more necessary properties (e.g., moisture-wicking properties). These substances may be dispersed in the sheath layer in the form of multiple particles. When water droplets or any other moisture accumulates on a first surface of the fabric (e.g., the inner surface in contact with the skin of the person wearing the fabric), the fabric, formed of one or more comfort fibers, absorbs water vapor from that surface. As part of this moisture-wicking process, water vapor can pass through the powder and may be transferred to a second surface of the fabric (e.g., the outer surface). This transfer may occur via capillary effects. This structure may also be softer and less ductile compared to existing materials (e.g., polyolefin-based fibers (PP and PE fibers) and polyurethane fibers).

[0212] (ii) A core with a similar structure and properties to core 111.

[0213] Figures 26A-B show comparative cross-sectional views of modern filaments and comfort fibers. Figure 26A shows a conventional multifilament, while Figure 26b shows a comfort fiber. The comfort fiber is shown to consist of a core made of foam axially encapsulated in a sheath. In other respects, the core is not foamed. Comfort fibers can be designed to combine the desired properties of multifilament filaments (e.g., softness, breathability, moisture absorption, etc.). A foam core can provide comfort fibers with multifilament properties such as softness and / or breathability. Figures 26A-B depict the traditional multifilament...How multifilament fibers exert their moisture-wicking properties. Figures 26A-B also depict comfort filaments that provide moisture-wicking properties as described herein.

[0214] Generally, multifilaments may be robust and rigid structures with limited deformability and shape control during weaving / knitting (or with less deformability and greater shape control compared to monofilaments during weaving / knitting). In their final state (e.g., as a fabric), multifilaments can be held in place solely by the frictional forces formed between adjacent multifilaments. During weaving / knitting, multifilaments may be confined to cross-shaped (e.g., warp and weft) patterns or unidirectional patterns (e.g., knitting).

[0215] Unlike multifilaments, comfort fibers can be shaped into different geometries during manufacturing processes (e.g., 3D printing) and are not limited to cross-shaped or unidirectional patterns. In their final state (e.g., as a fabric), comfort filaments can be held together by thermal welding.

[0216] The moisture-wicking effect of multifilament fibers may be based on several strategies, including any one, any combination of, or all of multilayer structures, chemical modification, and surface modification (e.g., plasma treatment). The mechanism by which multifilament fibers (especially quick-wicking / drying fabrics) reduce or eliminate skin moisture / water molecules is likely based on the capillary effect and hydrophobicity of the inner layer (skin contact layer), and the good moisture diffusion and evaporation facilitated by the hydrophilicity of the outer layer. The difference in capillary effect and hydrophilicity between the different layers is likely key to wicking and quick drying. If the fabric is not designed with the disclosed strategies to support quick drying, the drying process may be slower because both the high surface area and capillary effect limit the diffusion and elimination / desorption of moisture and water molecules. In contrast, the moisture-wicking-like effect of comfort fibers may be based on a different mechanism. Due to the presence of highly hydrophilic particles on the surface (e.g., cotton, wool, ramie, etc.) and the porous structure with surface protrusions that increase surface area, moisture and water molecules can be adsorbed and then absorbed into the comfort filament. The combination of hydrophilic particles and a large surface area can increase the absorption of moisture and water molecules from the skin into the comfort fiber. Specification 24 / 42 pages 28 CN 121100052 A

[0217] In one or more embodiments, rapid drying can also be achieved by the comfort filament structure due to any one, any combination or all of the following three mechanisms: (i) hydrophilic substances are concentrated only on the surface, thereby reducing the effective path of diffusion; (ii) capillary effects that hinder the drying process are reduced or minimized; (ii) the porous open structure of the printed fabric allows moisture transfer and evaporation. Therefore, comfort fibers may have desirable properties comparable to or even superior to multifilaments in some cases.

[0218] SEM micrographs demonstrating this concept are discussed subsequently.

[0219] Design aspects of comfort fibers can allow the use of techniques such as 3D printing, bonding, hot pressing, weaving, knitting, crocheting, and braiding.Comfort fibers can be processed (e.g., for design and construction) into finished products (e.g., clothing or outerwear) using techniques such as knotting, nonwoven processes, and other textile applications. 3D printing offers the advantage that the production of finished products using comfort fibers is not limited to larger textile mills; instead, individuals with 3D printers and related experience can manufacture products using comfort fibers at home or in relatively small facilities. The ability to use comfort fibers with properties similar to multifilaments may be advantageous in this regard, as multifilaments may not be suitable for producing finished products using technologies such as 3D printing. In this respect, comfort fiber technology can democratize the production of comfort textiles, providing smaller-scale clothing designers with more options for designing comfortable garments, while also enabling more localized production, thus reducing the impact on the supply chain. Designers can utilize customizable design options (e.g., any, any combination, or all of color, mechanical properties, chemical properties, texture, softness, moisture-wicking properties, breathability, etc.). The 3D printing and small-scale production offered by this process enable product customization and other advantages, such as more customized fit, customized design and design details, branding, fabric patterns, etc.

[0220] Another advantage of comfort fibers is that they can be recycled, thus providing environmentally friendly properties. This may be especially important considering that a large amount of non-biodegradable clothing ends up in landfills.

[0221] On one hand, the stages involved in producing comfort fibers may include one or both of filament production or 3D printing.

[0222] Filament production, as described above, involves filaments that can be used for 3D printing. Filaments can be produced in one of several ways. See Figures 28 and 43. For example, in one or some embodiments, as a first step, an elastomer (e.g., a thermoplastic elastomer (TPU or similar) or other thermoplastic polymer) can be mixed with natural powder by some process (e.g., twin-screw extrusion). This is illustrated, for example, step S201 in Figure 28. The amount of fiber mixed with the polymer can be between 5 and 40% by weight; however, lower or higher amounts can also be used. Any, any combination, or all of the powder content, powder / fiber type, and relevant aspect ratio can be relevant factors controlling the morphology of the final printed product (e.g., comfort fiber). In one or some embodiments, natural powder can be used for this purpose. Furthermore, in one or more embodiments, the orientation of the fibers and / or particles can be controlled by one or more processing techniques, such as any one, any combination of, or all of the following: printing angle; printing speed; particle length; relative thickness of the sheath (e.g., relative to particle length); or the viscosity of the polymer in which the fibers and / or particles reside in the sheath. Thus, for example, controlling the fiber orientation can be used to control the effect of the fibers on the user's skin in the molded product.

[0223] In one aspect, a twin-screw extruder (discussed further below) can be used in a melt / mixing process because its mixing capabilities produce a homogeneous mixture. This, in turn, results in better dispersion and distribution of particles within the polymer matrix, thereby reducing or minimizing agglomeration that could adversely affect filament properties and the printed article. The compounds produced by the twin-screw extrusion process may be one of the raw materials that can be used in the next step of filament production.

[0224] In a second step, the raw material can be converted into filaments (e.g., for 3D printing applications) via, for example, a co-extrusion process. See step S202 in Figure 28. In such a process, two different extruders can deliver the melt flow into a die. The melt flow can form a coaxial structure with a core layer and a sheath layer. In one aspect, the diameter of the filament is approximately 1.75 mm. Although 1.75 mm is more popular among users, the process is not limited to this specific diameter and other diameters (e.g., 2.8 mm, etc.) can also be produced. Generally, filament diameters greater than or less than 1.75 mm can be used. The two most common filament diameters for FDM / FFF are 1.75 mm and 2.85 mm; however, other diameters are also considered.

[0225] As mentioned above, various hardware is considered for producing the filaments. Figure 42 shows an example block diagram 4200 of the hardware, in which multiple extruders are used, such as a core extruder 4210 and a sheath extruder 4220. As mentioned above, the core can consist of a single material. Alternatively, the core can contain multiple materials. If the core consists of a single material, a single extruder can be used. If the core contains multiple materials (e.g., TPU and fibers / granules), a twin-screw extruder can be used.

[0226] Thus, in one or some embodiments, the raw material can be used as is (e.g., in its natural form, such as virgin plastic granules). Alternatively, the raw material can be used as a mixture containing different additives and / or polymers. Combining both is also considered. Furthermore, in one or some embodiments, the core layer can be primarily based on a thermoplastic elastomer, while other additives can be added during the extrusion process to impart different properties to the final filament / printed article.

[0227] Similarly, when the sheath comprises multiple materials, a twin-screw extruder can be used. Furthermore, the raw material for the sheath layer can be based on the mixture described herein, while other additives and / or polymers can be added during filament extrusion. These additives and / or polymers can be added to achieve desired properties. The sheath layer may be a cause of roughness on the filament surface; this aspect, along with material properties and subsequent printing processes, may determine the textile properties of the printed fabric.

[0228] In one or more embodiments, the extruder may perform one or more functions, such as any of the followingThe extruder can be used for: placing material into a barrel, container, etc.; melting material; mixing molten material; and extruding / pushing the mixed / molten material from an extruder into a die. In this regard, an extruder typically includes a gearbox / motor 4214, 4224 (e.g., cooperating with the gearbox to generate and transmit motion to rotate one or more screws), a feeder 4212, 4222 (e.g., feeding material into a barrel or container in a predetermined desired proportion), one or more screws 4216, 4226 (to rotate the components in the barrel; a single-screw extruder uses a single screw; a twin-screw extruder uses two screws), and a heater 4218, 4228 (e.g., heating the material in the barrel). Thus, in one embodiment, the core extruder 4210 may include a single-screw extruder (having a single screw) for mixing a single material. Alternatively, the core extruder 4210 may include a twin-screw extruder (having at least two screws) for mixing multiple materials. Furthermore, the sheath extruder 4220, which can mix multiple materials for the sheath, may include a twin-screw extruder comprising at least two screws. In one or more embodiments, one or more sensors may be placed inside or on a container or barrel to provide feedback to one or both of the heaters 4218, 4228 or the controller 4270 to regulate the heat generated by the heaters 4218, 4228. Although not shown in Figure 42, one or more pumps may be used to extrude the molten / mixed material.

[0229] Thus, the molten / mixed material from each of the core extruder 4210 and the sheath extruder 4220 may be directed to different portions of the die 4230, for example, the output from the core extruder 4210 is directed to the core portion 4232, while the output from the sheath extruder 4220 is directed to the sheath portion 4234. In one or more embodiments, the length of the die 4230 may be at least 100 mm or at least 200 mm. In practice, the material extruded into the die may be cooled to form filaments. Various methods are considered for cooling the material, such as using a traction device 4240 to draw the material from a cooling device 4250 (e.g., a cooling bath). A winding / collecting device 4260 can then be configured to collect the cooled filaments (e.g., a motor and / or spools).

[0230] FIG42 further illustrates a controller 4270, which may include one or more controllers. As shown, the controller 4270 may be located outside any one, any combination, or all of the core extruder 4210, sheath extruder 4220, traction device 4240, cooling device 4250, or winding / collecting device 4260. Alternatively or additionally, the controller 4270 may be located outside any one, any combination, or all of the core extruder 4210, sheath extruder 4220, traction device 4240, cooling device 4250, or winding / collecting device 4260. (See specification 26 / 42 pages 30 CN 121100052)A. The internal components of the device can be combined or all of the following. Furthermore, the central controller can control any one, any combination, or all of the core extruder 4210, sheath extruder 4220, traction device 4240, cooling device 4250, or winding / collecting device 4260. Alternatively or additionally, a local controller (which may reside in or be associated with) can be used to control (e.g., in response to commands sent by the central controller and / or based on its own analysis) any one, any combination, or all of the core extruder 4210, sheath extruder 4220, traction device 4240, cooling device 4250, or winding / collecting device 4260.

[0231] In practice, the controller 4270 can communicate via wired and / or wireless communication (e.g., shown in 4280). Furthermore, in practice, any, any combination, or all of the functions of the core extruder 4210, sheath extruder 4220, traction device 4240, cooling device 4250, or winding / collecting device 4260 can be automatically controlled by the controller 4270. For example, any, any combination, or all of the following: feeders 4212, 4222; gearboxes / motors 4214, 4224; one or more screws 4216; at least two screws 4226; heaters 4218, 4228; can be automatically controlled by controller 4270.

[0232] Figure 43 is a flowchart 4300 of an example of filament production. At 4310, materials can be fed into one or more machines, for example, a first set of materials for the core (which may consist of a single material or may contain multiple materials) is fed into a first machine, and a second set of materials for the sheath is fed into a second machine. At 4320, the materials are heated in the respective machines (e.g., the first set of materials is heated in the first machine, and the second set of materials is heated in the second machine). After the materials are melted, at 4330, the materials are mixed in the respective machines. At 4340, the mixed / molten material is extruded from the respective machine into different portions of the die (e.g., a first set of material for the core is extruded into the core portion of the die; a second set of material for the sheath is extruded into the sheath portion of the die). At 4350, the material is cooled to form filaments.

[0233] In one or more embodiments, the core / sheath area / diameter ratio (e.g., cross-section / area ratio) may be an important factor and can be adjusted / balanced to achieve the desired properties.

[0234] Regarding the material selection for the sheath layer, the final roughness can be adjusted by the amount of particles and / or fibers incorporated into the mixture in the manner described above. To densify (e.g., increase) the roughness, a larger amount of particles and / or fibers can be used, and vice versa if the roughness is to be minimized. In other respects, the surface roughness can also be controlled by changing the aspect ratio of the particles.

[0235] Figures 27A and B depict two different embodiments of the comfort fiber. Figure 27A shows a cross-section of the comfort fiber, whichThe relevant sheath contains a moderate load of particles. This sheath may contain a suitable amount of natural fibers. Figure 27B shows a cross-section of comfort fiber with a high load of particles in the relevant sheath. This sheath is characterized by a relatively high natural fiber content (high density). Changing the particle density in the sheath can be used to change the properties of the printed article / fabric.

[0236] Since the sheath is mostly kept relatively thin, the friction generated between the particles and / or fibers and the die wall during extrusion may push the particles toward the surface of the filament. This in turn produces roughness, masking the "plastic feel" of the filament or printed article. The resulting filaments from the die lip can be introduced into a cooling bath for cooling, and then dried and collected. The final product of this process is comfort fiber. In this regard, Figures 27A-B illustrate at least three things: (1) the shaped product obtained by 3D printing a filament with a core / sheath structure typically retains the core / sheath structure in the printed layer; (2) the shape may change (e.g., the diameter of the 3D printed layer in the shaped product is at least 1 / 2 or at least 1 / 4 smaller; see reduction from 1.75 mm to 0.4 mm); (3) one or more materials in the sheath of the filament may protrude from the 3D printed layer of the shaped product (e.g., fibers and / or particles in the filament (natural fibers as shown in Figures 27A-B) may be pushed outward from the sheath during the 3D printing of the layer, which may enhance the effect of the fibers and / or particles on the user's skin).

[0237] Different filaments with a range of properties can be produced by changing any one, any combination or all of the following: material composition; core / sheath ratio; extrusion processing parameters; extruder and die structure; etc.

[0238] 3D Printing (e.g., for article manufacturing) Specification 27 / 42 pages 31 CN 121100052 A In one aspect, comfort fibers can be used to manufacture finished products (e.g., clothing articles) by 3D printing. Referring to step S203 in Figure 28, comfort filaments are 3D printed to shape them into the desired final geometry. Comfort fibers can be introduced into a 3D printing machine / printer to shape them into the desired final geometry. Since the flow formed inside the print head is laminar, the coaxial structure of the comfort fibers can be maintained during printing, and the particles and / or fibers can be pushed to the outer surface of the printed layer. As the filaments are pulled down during printing, the overall diameter and the relative diameter of the core / sheath may decrease (depending on the die head). This may in turn push the particles and / or fibers out of the surface of the printed layer, thereby producing the desired (or expected) roughness. Another parameter that can control the degree of protrusion (and thus the roughness) is the ratio between the particle / fiber length and the sheath thickness. Longer fibers can cause noticeable protrusions on the surface, increasing surface roughness and fiber count. The aspect ratio of the particles to fibers can also affect stiffness. This can alter the printing process.The feel and softness of the fabric / textile. The resulting roughness, combined with material properties, can impart a feel / soft touch to the finished product (e.g., the final printed article / textile). In this regard, various aspects of comfort fibers, including one or both of roughness or stiffness, can be controlled based on the selection of particles / fibers, based on at least one aspect of the sheath (e.g., the thickness of the polymer in the sheath layer), or based on both particles / fibers and sheaths (e.g., the ratio between particle / fiber length and sheath thickness).

[0239] Any one, any combination, or all of the filament structure, material composition, printing processing parameters, printer structure, and printing geometry can determine the final properties of the fabric or textile made using comfort fibers. Properties can be adjusted at each production step, including any one, any combination, or all of breathability, wicking properties, humidity control, quick drying, hand feel, drape, and soft touch, to modify the final properties. Comfort fibers can also be processed using the flocking process described herein. As mentioned above, Figure 28 provides a flowchart depicting the process of manufacturing comfort fibers and making garment articles from comfort fibers.

[0240] In one embodiment, the printed fabric / textile using comfort fibers is not limited to or not restricted to the cross-weave and / or knitting directions commonly found in the textile industry; therefore, multi-directional patterns can be achieved by treating the comfort fibers accordingly.

[0241] Various characteristics of comfort fibers may include any one, any combination or all of the following: (i) avoiding the “plastic” or “synthetic” feel of other commercially available consumable filaments by adding a functional sheath; (ii) the surface roughness produced by the sheath after the printing process and / or the material composition of the layer may impart any one, any combination or all of the following properties to the printed articles made using comfort fibers: a soft touch; an air tunnel effect (e.g., when in contact with skin); a wicking effect; rapid drying; or a reduced coefficient of friction; (iii) the combination of materials in the sheath may be used to “adjust” or “modify” the roughness and the final properties described in (ii); (iv) the resulting core / sheath structure imparts any one, any combination or all of the following properties to the printed articles: a comfortable touch, flexibility, elasticity, breathability, air permeability, antimicrobial properties, high strength, moisture permeability, low weight (e.g., if foamed) or design flexibility (e.g., custom / tailor-made); (v) The combination of materials in the core / sheath layer and / or the ratio between the core and sheath can be used to customize the properties described in (iv). The printing process itself can provide additional design dimensions to modify the properties described in (iv); (vi) the final product printed using the above structure (without flocking) is recyclable; and (vii) the printed filaments can be directly printed on different types of substrates, including surfaces, textiles, clothing, plastics and polymers, metals, or ceramics, any combination or all of these.Page 28 / 42, CN 121100052 A

[0242] Post-processing of 3D printed fabrics considers various post-processing options for 3D printed fabrics. For example, in one or more embodiments, generally speaking, fabrics made of comfort fibers and not flocked may not have the feel and texture of flocked fibers, regardless of the filaments used to manufacture the fabric. In addition to flocking, one or more other processes may be applied to the printed material after 3D printing to obtain additional benefits, such as softness. These processes may include any one, any combination, or all of laser ablation, plasma treatment, surface texturing / roughening, or cleaning techniques.

[0243] For example, in one or more embodiments, laser ablation may include controlling at least one laser to direct laser energy (interchangeably referred to as laser radiation or radiant) to the surface of the formed product. In practice, the laser energy can alter at least a portion of the formed product, such as one or both of the following: (i) the surface; or (ii) the interior of the formed product, by generating heat within or on the formed product. For example, laser ablation can affect the surface of a molded product through heat (e.g., the feel or roughness of the surface; fibers and / or particles on the surface). Alternatively or additionally, laser ablation may affect the interior of the molded product (e.g., additives in the inner layers of the molded product may be affected or activated by laser energy).

[0244] As an example, laser ablation can be used on a molded product, such as a molded product formed from the above-described molding material 1 having at least one sheath 112. Specifically, the molded product may include one or more layers, wherein at least one, some, or all of the layers have a core / sheath configuration. In one or more embodiments, laser ablation may affect one, some, or all of the layers of the molded product, including one or both of the surface of the layer having a core / sheath configuration and / or the interior of the layer. Alternatively or additionally, the molded product may consist partially (or entirely) of layers having a core configuration, wherein laser ablation affects one, some, or all of the layers of the molded product, including one or both of the surface of the layer having a core configuration and / or the interior of the layer.

[0245] Specifically, laser ablation can affect a molded product in one or more of the following ways: (i) affecting the surface of the molded product (e.g., the surface of a layer of the molded product); or (ii) affecting the interior of the molded product (e.g., the interior of a layer). For example, laser ablation can generate heat in a sheath to affect one or more materials in the sheath (e.g., laser energy affects one or more materials in the sheath, such as affecting TPU with a sheath, thereby highlighting fibers and / or particles within the sheath of the molded product, and / or directly affecting fibers and / or particles within the sheath, as discussed further below).For example, laser ablation can create uniform and / or non-uniform patterns, such as micropatterns (e.g., textures), on the surface of a shaped product (e.g., a printed fabric or the top layer of another type of shaped product) to achieve different surface properties, such as any one, any combination, or all of the following: a soft touch; the feel of a textile; moisture management (e.g., wicking); or modulating surface energy (e.g., hydrophobic / hydrophilic properties of the surface). In one or more embodiments, the ablation pattern can be unidirectional or multidirectional and is not required to be limited to a specific geometry. For example, laser ablation can texture the surface of a shaped product, thereby achieving a predetermined geometry on the surface, such as a “hairy” structure that easily conforms to applied force. Upon close inspection, a typical garment surface releases tiny fibers. These released fibers, freed from the constraints of the main textile, can create a pleasant sensory experience. In this way, these tiny wanderings contribute to a softer touch, enhancing how the fabric responds to the skin. Against this backdrop, one purpose of using laser processing is to mimic those tiny “hairy” patterns that alter the surface to make it feel more comfortable and softer to the user. Ultimately, when the skin comes into contact with these tiny elements, the user can more easily bend them, thereby reducing the pressure applied to the skin. Furthermore, air passages are improved due to the gaps formed between these fibers and the skin. Theoretically, this geometry is ideal, but it is very difficult to achieve through printing processes; therefore, a secondary process using laser radiation is employed to achieve this effect. In response to the use of a laser with micron-level resolution (e.g., less than 1 mm), the effect of modifying the surface of the formed product can mimic this “hair-like” geometry, or at least create tiny elements on the surface of the formed product that can improve interaction with the skin.

[0246] Thus, in one or more embodiments, from a boundary perspective, the high resolution of the laser (e.g., micron-level or less than 1 mm) can be used to geometrically modify the surface to meet predetermined requirements and properties. Therefore, in one or more embodiments, laser ablation may affect the surface of the formed product (e.g., the surface of the sheath 112 in the formed product).

[0247] Alternatively or additionally, laser ablation can produce effects within the molded product, for example: (i) within the sheath of the layers of the molded product (e.g., affecting fibers and / or particles (e.g., fiber / particle 123) to have a more pronounced or prominent effect on the end user of the molded product (after 3D printing)); and / or (ii) within the core of the layers of the molded product. For example, laser ablation can expose protruding fibers by ablating a thin polymer film covering the surface of the fibers and / or particles. Thus, exposing fibers / particles within the sheath of the corresponding layer (e.g., the uppermost layer, thus exposed to the skin) can improve the effect due to close contact.Interaction with the skin allows for the improvement or maximization of the potential of fibers / particles embedded in the sheath. Exposing fibers and / or particles can also modulate “surface chemistry” to control / modulate the hydrophilic / hydrophobic properties of the surface. Thus, laser heat may expose fibers and / or particles closer to or reaching the surface of the molded product, thereby affecting the feel of the product. Alternatively or additionally, various additives in the sheath (e.g., fibers / particles 123) may be affected by laser heat (e.g., fibers / particles 123 may be activated by laser heat). Therefore, in one or more embodiments, the hydrophilic / hydrophobic properties of the surface may be determined by any one, any combination or all of the following: (i) creating a pattern on the surface of one or more layers of the molded product; (ii) exposing fibers / particles in the sheath; or (iii) activating or altering the chemical properties of the material in the sheath.

[0248] As another example, laser ablation can be used for molded products including a core (e.g., core 111), which may consist of a single substance and / or may contain additives (e.g., fibers and / or particles) and may not have any sheath. In this case, laser ablation may affect the surface of the molded product (e.g., the surface of core 111), and the fibers and / or particles in the core will have a more noticeable effect on the user after laser ablation. In this way, laser ablation may affect one or more surfaces of the molded product, potentially exposing fibers and / or particles to make them more readily accessible to the end user's skin. Alternatively or additionally, additives in core 111 can also be activated by laser heat. Alternatively, laser ablation can modify molded products comprising layers of a core of a single material (or composed of a core of a single material) by potentially removing a portion of the core material, thereby mechanically affecting the layers of the molded product (e.g., outer and / or inner layers).

[0249] As described above, laser ablation may affect one or more layers of the molded product. For example, laser ablation may affect the surface of a printed fabric that may come into direct contact with the user's skin. Alternatively or additionally, laser ablation may affect the inner layers of the molded product (e.g., layers that are effectively hidden from the user's perspective). Specifically, laser ablation can be applied in different directions to "hidden" layers of the molded product, which may be offset from the main linear body or may not be in direct contact with the skin (e.g., offset from one or more printed layers from the direction of the linear body in contact with the skin). Therefore, by selectively ablating the hidden surfaces, properties such as humidity management (e.g., wicking and hygroscopicity) and drape can be tuned.

[0250] As discussed in more detail below, laser radiation generated by the laser can be controlled to be directed in a controlled manner to any part of the molded product, such that the laser radiation can affect the surface of one or more layers of the molded product.And / or can affect the interior of one or more layers of the formed product (e.g., within the sheath and / or core).

[0251] In this way, laser ablation can modify the formed product in one of a variety of ways, including modifying the surface (e.g., producing different roughness, different textures, different patterns) and / or modifying the interior (e.g., activating additives therein and / or removing material to modify the mechanical structure and / or reinforcing the remaining material). In a particular example, the roughness / texture of the layers of the formed product can be determined by any one, any combination of, or all of the following: the ablation state; processing parameters; or the material's response to the laser. Generally, the finer the detail (e.g., the desired texture), the lower the roughness. In this regard, the specification of laser ablation 30 / 42 pages 34 CN 121100052 A strategic and controlled application can provide post-processing for the formed product after 3D printing. Thus, in one or more embodiments, laser ablation applied after 3D printing can effectively alter or improve the 3D printing process. In fact, the filament (e.g., monofilament or multifilament) prior to 3D printing may have predefined properties (e.g., roughness). 3D printing can alter these properties, such as changing the roughness of the filament during the production of the shaped product. In this way, laser ablation can control surface properties, such as roughness, either due to the 3D printing process or due to a predetermined feel desired on the surface after the 3D printing process.

[0252] Figure 44 shows a block diagram 4400 of an example laser irradiation system that can be used in conjunction with a 3D printer 271. Specifically, Figure 44 shows a shaped product that can be printed by the 3D printer 271. In one or more embodiments, the shaped product can be automatically conveyed (e.g., via a conveyor, etc.) to a laser irradiation device, which may include any one, any combination, or all of the following: laser 4410; lens 4420; support 4450; motor / robot 4440; or controller 4270. Alternatively, the product may also be manually conveyed to the laser irradiation system.

[0253] Furthermore, it is conceivable to use one or more lasers, such as a single laser / lens combination or multiple corresponding laser / lens combinations. In one or more embodiments, laser 4410 may include a UV laser. Alternatively, it is conceivable to use lasers of other wavelengths. Furthermore, laser 4410 may include one or more laser emission parameters, which can be controlled by controller 4270, as discussed further below. Additionally, various aspects of the lens can be selected for a predetermined laser radiation application. Specifically, any one, any combination, or all of the following laser or lens parameters can be selected and / or controlled by controller 4270: laser power and / or intensity; laser resolution (e.g., higher resolution can be achieved through...).The following parameters may be considered: (1) leading to more accurate patterning and finer details on the ablation surface; (2) laser wavelength; (3) lens size (e.g., diameter); (4) distance from the lens to the substrate and / or focal position (e.g., which may be affected by the movement of one or both of the lens 4420 or the support 4450 via the motor / robot 4440, as discussed further below); (5) field size; (6) scanning speed (e.g., a higher rate may result in a faster processing speed; scanning speed may further affect potential heat buildup within or on the layer of the formed product); (7) pulse energy (e.g., higher energy; deeper and wider features); (8) pulse frequency (e.g., a higher rate may result in a faster processing speed; pulse frequency may further affect potential heat buildup within or on the layer of the formed product); (9) geometry of the ablation pattern; (10) distance between lines, line depth, etc. (e.g., the geometric pattern may simply be the desired geometry / texture; however, the final texture may be determined by a combination of processing parameters and the desired geometry); or (11) geometry of the surface to be treated (e.g., geometry of printed fabric).

[0254] Other processing parameters that may affect the application of laser radiation may include: the material composition of the sheath; and / or the core / sheath ratio. For example, with regard to the material composition of the sheath, the response of the laser to the substrate may be highly influenced by the material chemistry. In this regard, the response of the laser can be modulated to some extent using different additives (which may be added to one or both of the core or sheath). In this regard, additives may also be introduced into the sheath if it is desired that the laser penetrates the corresponding layer more deeply to obtain specific properties. In addition, the core / sheath ratio may affect the laser response, for example, when a specific additive that may enhance the response is introduced into the sheath. Consider various materials or additives that react or change in response to laser radiation. For example, carbon-based materials (e.g., carbon black) can enhance the laser response. Alternatively or additionally, different pigments can improve the laser response of polymers (e.g., one or both of tin and antimony can be used to increase the laser response of polymers). As another example, shelf additives can be used to increase the laser ablation response of polymers.

[0255] In addition, the molded product 4430 may be held in or on a support 4450. In one or more embodiments, the molded product 4430 comprises one or more layers. In one or more embodiments, one, some, or each layer of the molded product 4430 may be composed of a core / sheath construction. Alternatively or additionally, one, some, or each layer of the molded product 4430 may be composed of a core construction (without a sheath). In either case, the laser radiation generated by the laser 4410 may affect one or more layers (e.g., on the surface of the respective layer and / or inside the respective layer).

[0256] Figure 44 further illustrates the motor / robot 4440 and the controller 4270. As described above, the controller 4270 can be configured to control one or more devices, such as any one, any combination, or all of the following: laser 4410; bracket 4450; or motor / robot. In practice, controller 4270 can be configured to control one or more parameters associated with laser 4410 (e.g., any one, any combination, or all of the following: laser power / intensity; laser resolution; laser wavelength; scanning speed; pulse energy; pulse frequency, etc.). Alternatively or additionally, controller 4270 can be configured to control motor / robot 4440 to mechanically manipulate and / or move various objects. As an example, controller 4270 can be configured to control motor / robot 4440 to move shaped product 4430 to holder 4450.

[0257] As another example, controller 4270 can be configured to control motor / robot 4440 to move lens 4420 and laser 4410 relative to each other (e.g., keeping laser 4410 stationary and moving lens 4420; keeping lens 4420 stationary and moving lens 4420). The laser 4410 is stationary and moved; both the laser 4410 and the lens 4420 are moved. In this way, the relative motion of the laser 4410 and the lens 4420 can be achieved on one of a plurality of axes, such as along any one, any combination or all of the x-axis, y-axis or z-axis (e.g., defining movement in any direction).

[0258] As another example, the controller 4270 may be configured to control the motor / robot 4440 by moving one or both of the laser 4410 / lens 4420 and the support 4450 (or the support 4450 / formed product 4430) (e.g., keeping the laser 4410 / lens 4420 stationary and moving the support 4450; keeping the support 4450 stationary and moving the laser 4410 / lens 4420). The laser 4410 / lens 4420 and the support 4450 are moved, thereby moving the laser 4410 / lens 4420 and the support 4450 (or the support 4450 / formed product 4430) relative to each other. In this way, the relative movement of the laser 4410 / lens 4420 and the support 4450 can be achieved on one of a plurality of axes, such as along any one, any combination or all of the x-axis, y-axis or z-axis (e.g., defining movement in any direction).

[0259] In one or more embodiments, the controller 4270 may be configured to control the focus of the laser radiation generated by the laser 4410 relative to the formed product 4430 so as to apply the laser radiation to or onto various portions of the formed product 4430 in a predetermined manner. As described above, laser radiation can be applied to change one or more layers of the formed product 4430.In one example, the outer layer of the molded product (which may come into contact with the user's skin) can be altered by laser radiation. In this case, the laser radiation may change the surface of the outer layer (e.g., the surface that directly contacts the user's skin), thereby creating patterns, etching, etc. Alternatively or additionally, the laser radiation may alter the interior of the outer layer (e.g., the interior of the sheath and / or core in a sheath / core structure of the outer layer; the interior of the core in a core structure of the outer layer). As an example, the laser radiation may include laser ablation, thereby effectively removing portions or materials from the outer layer. In a particular example, the laser radiation may ablate TPU (or other materials) in the sheath of the corresponding outer layer, thereby potentially enhancing other materials in the corresponding outer layer (e.g., fibers and / or particles in the outer sheath) and / or potentially altering the mechanical properties of the corresponding outer sheath. This may be similar to applying PVA (or another water-soluble material) to the outer layer so that, after cleaning, the PVA can be removed from the outer layer (e.g., from the outer sheath). Instead, because the laser radiation can be controlled or guided, the ablation can be more precisely controlled to more selectively remove material from the outer layer. Alternatively or additionally, in another specific example, laser radiation can ablate the TPU (or other material) in the core of the corresponding outer layer, thereby potentially enhancing other materials in the core of the corresponding outer layer or potentially altering the mechanical properties of the core of the corresponding outer layer. In another specific example, laser radiation can alter specific additives in the corresponding outer layer (e.g., in the sheath and / or core), which can effectively enhance the responsiveness of the specific additives.

[0260] In another example, the inner layer of the molded product 4430 (which may not come into contact with the user's skin) can be modified by laser radiation. As described above, the inner layer (or hidden layer) of the molded product 4430 can be modified to selectively apply laser radiation to the hidden surface or selectively ablate portions of the surface or interior of the corresponding inner layer to modify the properties of the molded product 4430, such as moisture management and / or drape. In one particular example, laser radiation can effectively remove portions or materials of an inner layer (e.g., remove some TPU from the corresponding inner layer), which may affect the mechanical properties of the inner layer and / or reinforce other materials in the inner layer (in the sheath and / or core of the corresponding inner layer). In this respect, the ablation portion can be more tightly controlled to more selectively remove material from the hidden layer, since the laser radiation can be controlled or directed. In another particular example, laser radiation can alter specific additives in the corresponding inner layer (e.g., in the sheath and / or core), which can effectively enhance the response of the specific additives.

[0261] As described above, the controller 4270 can be configured to direct the laser radiation generated by the laser 4410 to the molded product.A predetermined portion in or above 4430. For example, as described above, the focus of the laser radiation generated by laser 4410 can be modified by controller 4270. In this respect, the focus of the laser radiation can be positioned relative to the corresponding layer (e.g., outer and / or inner layer) in the molded product 4430 in a predetermined manner to affect the corresponding layer in the molded product 4430. Thus, the focus of the laser radiation can be positioned relative to the corresponding layer in one of a variety of ways, including any, any combination of, or all of the following: "above" the corresponding layer (e.g., closer to laser 4410), within the corresponding layer, or "below" the corresponding layer (e.g., away from laser 4410). In this way, controller 4270 can guide the laser radiation in a very directional and precise manner to achieve the results discussed herein.

[0262] For this purpose, FIG45 shows an example flowchart 4500 for performing laser ablation. At 4510, the molded product is placed in or on a support. At 4520, one or both of the laser / lens or supports are moved to prepare for laser emission. At 4530, the laser is operated (e.g., simultaneously with and / or when the laser / lens or support is stationary) to direct laser radiation onto or within a predetermined layer of the formed product.

[0263] Plasma treatment is another example of post-treatment of formed products. In one or more embodiments, plasma surface treatment can be used to modify the surface properties of the formed product, such as surface energy, functionalization, and surface cleaning (e.g., removal of contaminants). In this regard, plasma treatment can be used to perform any one or both of the following: modifying the sheath composition (e.g., the chemical properties in the sheath can be tuned to increase / decrease reactivity and response to plasma; and creating a geometric pattern on the surface to be treated). Various parameters of the plasma treatment can be modified, such as any one, any combination, or all of the following: adjusting the plasma power (e.g., higher power may result in more extensive modification and / or potential degradation); the duration of plasma exposure; modifying the plasma pressure (e.g., lower pressure: higher energy particles, deeper modification); gas composition (e.g., which can determine the active material, resulting in specific surface modifications).

[0264] Consider using various hardware to perform plasma processing, examples of which are shown in block diagram 4600 of Figure 46. Specifically, Figure 46 shows a shaped product that can be printed by 3D printer 271. In one or more embodiments, the shaped product can be automatically conveyed (e.g., via a conveyor, etc.) to a plasma processing apparatus that may include any one, any combination of, or all of the following: a vacuum plasma chamber device 4610; a gas injector 4620; a gas pump 4640; a motor / robot 4440; or a controller 4270. Alternatively, the product may be manually conveyed to the plasma processing apparatus.

[0265] Specifically, Figure 46 illustrates a vacuum plasma chamber apparatus 4610 (interchangeably referred to as a plasma chamber or plasma housing), which includes a plasma generator 4630 and electrodes 4632, and in which a shaped product 4430 can be placed. In one or more embodiments, plasma processing can be performed in a evacuated vacuum plasma chamber apparatus 4610 (e.g., vacuum plasma). Before allowing gas to enter, air can be pumped out of the chamber or housing using an air pump 4640 and a gas line 4642. Gas can then flow into the vacuum plasma chamber apparatus 4610 at low pressure using a gas injector 4620 and a gas line 4622. This can be done before any energy (e.g., electricity) is applied. Thus, plasma processing performed at low temperatures can process heat-sensitive materials, such as materials within one or more layers of the shaped product 4430.

[0266] In one or more embodiments, the plasma generator 4630 may generate the necessary radio frequency (RF) power to generate and sustain plasma within the plasma chamber of the vacuum plasma chamber apparatus 4610, as described on pages 33 / 42 of the specification (CN 121100052 A). Plasma generation can be achieved by adding sufficient energy to the gas using a gas injector 4620 in the vacuum plasma chamber apparatus 4610 to release electrons from their atoms or molecules, allowing the resulting ions and electrons to coexist. Therefore, in one or more embodiments, one method of generating such ionized gas or plasma is to introduce gas into the space between two parallel electrodes 4632 using the gas injector 4620. One electrode may be grounded, while the other electrode may be powered by the RF generator. Thus, capacitive or inductive coupling between the electrodes can excite the gas, generating plasma. In one or more embodiments, the RF power frequency used to generate plasma may be 13.56 MHz. Other frequencies are also considered, such as 40 kHz and 2.45 GHz.

[0267] FIG46 further illustrates a controller 4270, which can be configured to control any one, any combination, or all of the following: vacuum plasma chamber apparatus 4610, motor / robot 4440, gas injector 4620, or gas pump 4640. For example, the controller 4270 can control the motor / robot to move the shaped product 4430 into and / or out of the vacuum plasma chamber apparatus 4610. As another example, the controller 4270 can control the gas pump 4640 to pump gas from the vacuum plasma chamber apparatus 4610 (e.g., before and / or after plasma treatment). As another example, the controller 4270 can control the gas injector 4620 to pump gas into the vacuum plasma chamber apparatus 4610. As yet another example, the controller 4270 can control the vacuum plasma chamber apparatus 4610 to generate plasma.

[0268] Figure 47 shows an example flowchart 4700 for performing plasma processing. At 4710, the shaped product to be processed is introduced into a plasma chamber, which is typically a vacuum chamber. The chamber is then evacuated to create a low-pressure environment.

[0269] At 4720, a gas is introduced into the vacuum plasma chamber. In one or more embodiments, the gas may include argon, oxygen, or nitrogen. Furthermore, in one or more embodiments, the gas may be introduced into the vacuum plasma chamber at a certain flow rate to ensure the correct process pressure to produce stable plasma.

[0270] At 4730, plasma is generated by ionizing the gas. Specifically, the gas may be ionized using an electrical signal that may be DC (direct current), RF (radio frequency), or microwave to generate plasma. The plasma may include (or consist of) an ionized gas cloud containing ions, electrons, and neutral atoms or molecules.

[0271] At 4740, surface modification is performed using plasma. Specifically, when plasma comes into contact with the material, the plasma may chemically modify the outer surface of the shaped product. In addition, plasma can also be used to add or remove functional groups to the outer layer of molded products, increase wettability, or improve adhesion.

[0272] At 4750, the vacuum plasma chamber is restored to atmospheric pressure and the molded product is removed from the vacuum plasma chamber. Specifically, once the desired surface modification is achieved, the vacuum plasma chamber can be restored to atmospheric pressure using air or nitrogen, and then the molded product can be removed from the vacuum plasma chamber.

[0273] Other processes can be performed separately from or additionally to laser ablation and / or plasma treatment. As an example, in one or more embodiments, the flocking process can be a relatively rapid process that can immediately alter the properties of the printed object / surface while imparting any one, any combination, or all of the following properties (depending on the flocking fibers): textile feel; soft and comfortable touch; wicking effect; adjustment / change of surface polarity (e.g., hydrophilic / hydrophobic); a more natural feel against the skin; breathability; moisture transfer; quick drying; warmth; antibacterial properties; property gradient / gradation within the same product (e.g., through selective flocking); control of density as a way to adjust surface properties; or design flexibility (custom / tailor-made).

[0274] Furthermore, in one or more embodiments, other properties that may not be identified in textile applications but may be improved by flocked printed articles may include any one, any combination, or all of the following: thermal insulation; electrical conductivity and antistatic behavior; or sound absorption.

[0275] Garments made using comfort fibers may include one or more of the desirable qualities of the comfort fibers described herein. Instruction manual, pages 34 / 42, 38 CN 121100052 A. With the development / advances of new 3D printing technologies based on melt processing, robotic arm-based direct extrusion and co-extrusion can be used as...Comfort fiber production is part of the textile production process. One aspect includes direct extrusion / co-extrusion using one or more robotic arms (as part of one or more robots). In addition to producing finished materials via 3D printing, filaments (comfort fibers) can also be used to manufacture comfort fiber materials using other textile applications, such as any one, any combination, or all of the following: bonding, hot pressing, weaving, knitting, crocheting, braiding, nonwovens, and other textile techniques. These techniques can be implemented using filaments in their original form (e.g., unprinted) or by printing filaments into yarn or other geometric patterns and using the printed yarn / pattern form for textile technology. Additional heating and / or welding and / or bonding techniques (e.g., hot pressing, hot air, high-frequency welding, adhesives, etc.) can be employed to aid in bonding / welding or securing the material and adding additional properties.

[0276] On one hand, moisture regain (%) can be used as a measure of the comfort level of the material. The following lists the moisture regain percentages of different materials: wool: 15; cotton: 8.5; ramie: 12; polyester: 0.4; nylon: 4.5; polypropylene: 0; TPU: 0.4-0.8%. Generally, a higher moisture regain percentage produces a better hand feel.

[0277] Figures 29A-38B show scanning electron microscope (SEM) images of different types of fibers. Figures 29A-B show TPU-based monofilaments. Cross-sectional views (as shown in Figure 29A) and external surface views (as shown in Figure 29B) are shown. The cross-sectional view in Figure 29B shows a clear and uniform cross-section, while the magnified external surface view in Figure 29B shows a smooth shape with less roughness.

[0278] Figures 30A-B depict core / sheath filaments with cotton powder in the sheath layer. Cross-sectional views (as shown in Figure 30A) and magnified external surface views of the sheath layer (as shown in Figure 30B) are shown. The filaments shown in Figures 30A-B are 1.75 mm filaments. A cross-sectional view (as shown in Figure 30A) illustrates the concept of the core axially encapsulated within a sheath. The particles are visible only within the sheath layer. In an enlarged view of the outer surface (as shown in Figure 30B), the cotton particles inside the sheath layer are visible. This type of filament can be used to construct comfort filaments.

[0279] Figures 31A-B depict enlarged views of the outer surface of a core / sheath filament with cotton particles in the sheath layer at different scales. Figure 31A shows a view depicting the outer surface of the filament, showing the roughness around the sheath layer due to the presence of the particles. Figure 31B shows a further enlarged view of the outer surface, revealing the roughness profile in the micrometer range. This type of filament can be used to construct comfort filaments.

[0280] Figures 32A-B depict a core / sheath filament with wool particles in the sheath layer. A cross-sectional view (as shown in Figure 32A) and an outer surface view (as shown in Figure 32B) are presented. The filament shown in Figures 32A-B is a 1.75 mm filament. The cross-sectional view (as shown in Figure 32A)Figure 32A-B illustrates the concept of the core axially encapsulated within a sheath. The particles are only visible within the sheath layer. In a magnified view of the outer surface (as shown in Figure 32B), the wool particles inside the sheath layer are visible. This type of filament can be used to construct comfort filaments.

[0281] Figures 33A-B depict magnified views of the outer surface of the core / sheath filament, with wool particles in the sheath layer. Figure 33A shows a view depicting the outer surface of the filament, showing the roughness around the sheath layer due to the presence of the particles. Figure 33B shows a further magnified view of the outer surface, revealing the roughness profile in the micrometer range. This type of filament can be used to construct comfort filaments.

[0282] Figures 34A-B depict cross-sectional views of a 3D-printed fabric based on core / sheath filaments (e.g., comfort filaments), with cotton particles in the sheath layer. Figure 34A shows a cross-section of a printed article based on core / sheath filaments, with cotton particles in the sheath layer. Roughness caused by the particles is seen on the outer surface of the printed layer. Figure 34B shows similar views of different sections of the fabric.

[0283] Figures 35A-B depict cross-sectional views of 3D-printed fabrics based on core / sheath filaments (e.g., comfort filaments), where cotton particles are contained in the sheath layer. Figure 35A depicts a cross-section of a printed article based on core / sheath filaments, where cotton particles are contained in the sheath layer. The particles are visible around the periphery of the sheath layer. Figure 35B depicts an enlarged view of the cross-section of the printed article. The cotton particles are visible around the periphery and on the outer surface (arrow 370 in Figure 35B).

[0284] Figures 36A-B depict printed fabrics based on TPU monofilaments (e.g., modern filaments). Figure 36A shows a top view of a printed article based on TPU monofilaments. The smooth surface of the printed layer is visible in the photograph. Figure 36B shows an enlarged view of the top view, demonstrating the smooth surface of the printed layer.

[0285] Figures 37A-B depict cross-sectional views of the printed fabric based on TPU monofilaments shown in Figures 36A-B. Figure 37A shows a cross-sectional view of a printed article based on TPU monofilament fibers. The outer surface of the filament is smooth, eliminating shear bands in the cross-section due to shearing the sample during the preparation process. Figure 37B shows an enlarged view of the cross-section of the printed article, showing that the outer surface of the printed article is smooth with minimal roughness.

[0286] Figures 38A-B depict the final product (e.g., printed fabric) based on core / sheath filaments (e.g., comfort fibers), where the sheath layer contains cotton particles. Figure 38A shows a top view of the print bed side with multiple layers. Figure 38B shows a top view of a printed article based on comfort fibers, where the sheath layer contains cotton particles. The protruding cotton particles and the high porosity (pores) generated on the surface can accelerate the absorption of moisture and water molecules from the skin (e.g., hygroscopic effect). Figure 38A depicts a top view.The magnified image shows how the particles protrude from the surface and how these particles, together with the porous structure generated on the surface, accelerate the absorption of moisture and water molecules from the skin (hygroscopic effect).

[0287] Chemical resistance to seawater (saltwater) and chlorinated water To analyze the effects of different water / aqueous media on the chemical resistance of different comfort filaments, different laboratory tests were performed. The two media tested in this regard were: (1) Seawater (e.g., saltwater): Chemical resistance was determined using tensile tests before and after exposure, measuring stress (e.g., modulus) at the following elongations: 100%, 200%, and 300%.

[0288] (2) Chlorinated water (tests performed according to ISO 17608:2015): Chemical resistance was determined using tensile tests before and after exposure, measuring stress (e.g., modulus) at the following elongations: 100%, 200%, and 300%.

[0289] The tested filaments / comfort fibers were: (i) TPU monofilaments (Φ = 1.75 mm); (ii) TPU-based core / sheath filaments containing wool powder in the sheath layer (Φ = 1.75 mm); and (iii) TPU-based core / sheath filaments containing cotton powder in the sheath layer (Φ = 1.75 mm). The test results showed that, under neutral / room temperature conditions (23°C, 50% RH), the core / sheath filaments outperformed the TPU monofilaments, exhibiting higher modulus at 100%, 200%, and 300% elongation.

[0290] A similar trend was observed when the filaments were exposed to seawater, with both wool and cotton core / sheath filaments showing higher modulus at 100%, 200%, and 300% elongation. The test results confirm that, compared to TPU monofilaments, the core / sheath filaments exhibit better chemical resistance to seawater, demonstrating higher modulus and dimensional stability.

[0291] The core / sheath comfort filaments exhibited a similar trend in chlorinated water, confirming that adding a wool-based sheath layer can provide better chemical resistance compared to TPU monofilaments. For all tested chlorinated media (according to ISO 17608:2015), the wool-based sheath layer showed higher modulus at 100%, 200%, and 300% elongation, implying that the material may be less sensitive to chlorinated environments. This further confirms that wool-based sheath filaments can have better chemical resistance compared to TPU monofilaments. This offers the advantage that fabrics constructed using comfort filament technology may be more durable than fabrics made with conventional TPU fibers. In this respect, environments such as washing (e.g., laundry), exposure to seawater, etc., may wear down garments constructed from comfort fibers faster than those constructed from TPU fibers.

[0292] From the above, it is confirmed that the core / sheath structure can not only have higher modulus and dimensional stability but also better chemical resistance and less susceptibility to the test media.

[0293] As shown in Figure 39, Table 1 summarizes the tensile test results at 100%, 200%, and 300% elongation under standard conditions (23°C, 50% RH). Data are expressed as absolute modulus (MPa units).

[0294] As shown in Figure 40, Table 2 summarizes the tensile test results for chemical resistance to seawater and chlorinated water, using the modulus (recorded stress) at 100%, 200%, and 300% elongation as a measure of chemical resistance. Data (modulus) are expressed as the reduction in modulus (%) compared to a reference sample of the same series / filament (23°C, 50% RH).

[0295] The hygroscopicity of comfort filaments was studied to investigate the advantages of core / sheath structures in terms of hygroscopicity. Hygroscopicity may also be related to the comfort of the fiber and fabric.

[0296] The tests were conducted in a humidity chamber at a temperature of 40°C and a relative humidity of 95% for 2 hours and 6 hours. The samples were first dried and weighed before being placed in the humidity chamber.

[0297] Three different types of filaments / comfort fibers were tested: (i) TPU monofilament (Φ = 1.75 mm); (ii) TPU-based core / sheath filaments with wool powder in the sheath layer (Φ = 1.75 mm); and (iii) TPU-based core / sheath filaments with cotton powder in the sheath layer (Φ = 1.75 mm).

[0298] As can be seen from the test results summarized in Table 3 of Figure 41, the core / sheath structure absorbed a higher level of moisture, especially in the case of the wool-based sheath layer, where the moisture content was almost double that of the TPU monofilament (90% higher). The cotton-based sheath layer also showed a higher moisture content compared to the TPU monofilament, but the absorption rate was slower compared to the wool base layer. This evidence supports the view that core / sheath filaments in the form of comfort fibers / filaments may be suitable candidates for textile applications, such as for clothing and skin contact fabrics / fibers due to their associated high moisture absorption.

[0299] Considering that PET (polyethylene terephthalate) has a maximum water absorption of 0.8%, the test results confirm that the performance of comfort filaments may be superior to other multifilaments, highlighting their advantages in textile applications.

[0300] This disclosure is not limited to the above embodiments, but can be substantially replaced by structures that are substantially the same as those shown in the above embodiments, structures that have the same effect, or structures that can achieve the same purpose.

[0301] As mentioned above, all aspects of the processing can be controlled by a computer. In this regard, in such computer-controlled applications, current technological advancements must be used in conjunction with a computer programmed according to the disclosure herein. By way of example only, various devices disclosed in this application may include a computer or devices that can work in conjunction with a computer (e.g., performed by a computer).(e.g., as shown in Figures 19, 22, 42, 44, and 46). For example, computing functionality can be embodied in control electronics 285 or controller 4270. Thus, computing functionality can reside within any electronics discussed herein. By way of example only, Figure 48 is a diagram of an exemplary computer system 4800 that can be used to implement the methods described herein (including flowcharts). A central processing unit (CPU) 4802 is coupled to a system bus 4804. CPU 4802 can be any general-purpose CPU, although other types of architectures of CPU 4802 (or other components of the exemplary computer system 4800) may also be used, as long as CPU 4802 (and other components of the computer system 4800) support the operations described herein. Those skilled in the art will understand that although only a single CPU 4802 is shown in Figure 48, additional CPUs may be present. Furthermore, computer system 4800 may include a networked multiprocessor computer system, which may include a hybrid parallel CPU / GPU system. CPU 4802 can execute various logical instructions in accordance with the various teachings disclosed herein. For example, CPU 4802 can execute machine-level instructions to process according to the operational flow described herein.

[0302] Computer system 4800 may also include computer components, such as non-transitory computer-readable media. Examples of computer-readable media include computer-readable non-transitory storage media, such as random access memory (RAM) 4806, which may be SRAM, DRAM, SDRAM, etc. Computer system 4800 may also include additional non-transitory computer-readable storage media, such as read-only memory (ROM) 4808, which may be PROM, EPROM, EEPROM, etc. RAM 4806 and ROM 4808 store user and system data and programs, as is known in the art. In this respect, computer-readable media may include executable instructions to perform any one, any combination, or all of the blocks in the flowcharts of Figures 23, 28, 43, 45, and 47. The computer system 4800 may also include an input / output (I / O) adapter 4810, a graphics processing unit (GPU) 4814, a communication adapter specification 4822, a user interface adapter 4824, a display driver 4816, and a display adapter 4818.

[0303] The I / O adapter 4810 can connect additional non-transitory computer-readable media (e.g., storage device 4812, including, for example, hard disk drives, optical disc (CD) drives, floppy disk drives, tape drives, etc.) to the computer system 4800. When the RAM 4806 is insufficient to meet the memory requirements associated with storing data used for the operation of the present invention, storage may be used.Devices. The data storage of computer system 4800 can be used to store information and / or other data disclosed herein that has been used or generated. For example, storage device 4812 can be used to store configuration information or add-ons according to the present technology. In addition, user interface adapter 4824 couples user input devices (e.g., keyboard 4828, pointing device 4826, and / or output devices) to computer system 4800. Display adapter 4818 is driven by CPU 4802 to control the display on display device 4820, for example, to present information (e.g., images generated according to the methods described herein) to the user.

[0304] The architecture of computer system 4800 can vary as needed. For example, any suitable processor-based device can be used, including but not limited to personal computers, laptops, computer workstations, and multiprocessor servers. In addition, the present technology can be implemented on application-specific integrated circuits (ASICs) or very large-scale integrated circuits (VLSIs). In fact, those skilled in the art can use any number of suitable hardware structures capable of performing logical operations according to the present technology. The term “processing circuit” includes hardware processors (e.g., those in the hardware devices mentioned above), ASICs, and VLSIs. The data input to computer system 4800 may include various plugins and library files. The input data may also include configuration information.

[0305] The foregoing detailed description is intended to be understood as an illustration of alternative forms of the invention and not as a limitation thereof. Only the following claims (including all equivalents) are intended to define the scope of the invention. Furthermore, it should be noted that any aspect of any preferred embodiment described herein may be used alone or in combination with each other. Finally, those skilled in the art will readily recognize that, in preferred embodiments, some or all of the steps in the disclosed methods are performed using a computer, making the method computer-implemented. In this case, the resulting model discussed herein can be downloaded or saved to computer memory.

[0306] The following exemplary embodiments of the invention are also disclosed: Embodiment 1: A method for producing filaments (e.g., a method at least partially or entirely implemented by a computer), comprising: extruding a first set of materials for a filament core and a second set of materials for a filament sheath using one or more extruders, wherein the second set of materials comprises at least one or both of fibers or granules; using a core portion and a sheath portion of at least one die to guide the first set of materials and the second set of materials extruded from the one or more extruders, respectively; and forming filaments by cooling the first set of materials and the second set of materials during or after using the core portion and the sheath portion of the at least one die.

[0307] Embodiment 2: The method of Embodiment 1: wherein the one or more extruders include at least a first [missing information - likely a first set of materials] for melting, mixing and extruding the first set of materials.An extruder and at least a second extruder for melting, mixing and extruding a second group of materials; and wherein the at least second extruder comprises a twin-screw extruder.

[0308] Embodiment 3: The method of Embodiment 1 or 2: wherein the second group of materials comprises at least one thermoplastic polymer and at least one or two of the fibers or granules.

[0309] Embodiment 4: The method of any one of Embodiments 1-3: wherein the second group of materials further comprises a water-soluble polymer.

[0310] Embodiment 5: The method of any one of Embodiments 1-4: wherein the diameter of the core portion of the at least one die is at least five times the thickness of the sheath portion of the at least one die.

[0311] Embodiment 6: A method for processing a 3D printed product (e.g., a method at least partially or entirely computer-implemented), the method comprising: receiving a 3D printed product; and, after receiving the product, subjecting the product to at least one of laser irradiation treatment or plasma treatment.

[0312] Embodiment 7: The method of Embodiment 6: wherein the molded product comprises one or more layers; and wherein, after 3D printing the molded product, laser radiation is applied to the surface or interior of at least one of the one or more layers.

[0313] Embodiment 8: The method of Embodiment 6 or 7: wherein the one or more layers comprise an outer layer having a surface configured to contact the skin of a user of the molded product; and wherein applying laser radiation comprises laser ablation, which forms a pattern on the surface of the outer layer to alter the sensation of the outer layer upon contact with the user's skin.

[0314] Embodiment 9: The method of any one of Embodiments 6-8: wherein the one or more layers comprise an outer layer having a surface configured to contact the skin of a user of the molded product; and wherein applying laser radiation alters the interior of the outer layer.

[0315] Embodiment 10: The method of any one of Embodiments 6-9: wherein applying laser radiation comprises laser ablation of at least a portion of the interior of the outer layer.

[0316] Embodiment 11: The method of any one of Embodiments 6-10: wherein the interior of the outer layer comprises one or both of at least one thermoplastic polymer and fibers or granules; and wherein laser ablation comprises removing at least a portion of the at least one thermoplastic polymer to enhance the effect on the skin of the user of the molded product.

[0317] Embodiment 12: The method of any one of Embodiments 6-11: wherein the one or more layers comprise an inner layer having a surface not configured to contact the skin of the user of the molded product; and wherein laser radiation is applied to the inner layer of the molded product.

[0318] Implementation Scheme 13: The method of any one of Implementation Schemes 6-12: wherein laser radiation is applied to an inner layer of the molded product to ablate at least a portion of the inner layer.

[0319] Implementation Scheme 14: The method of any one of Implementation Schemes 6-13: wherein ablation of the at least a portion of the inner layer alters at least one of moisture management or drape of the molded product.

[0320] Implementation Scheme 15: The method of any one of Implementation Schemes 6-14: wherein the molded product comprises one or more layers; and wherein, after 3D printing the molded product, a plasma treatment is applied to the surface of at least one of the one or more layers.

[0321] Implementation Scheme 16: The method of any one of Implementation Schemes 6-15: wherein the plasma treatment cleans the surface of at least one of the one or more layers.

[0322] Embodiment 17: An apparatus configured to process a 3D-printed product, the apparatus comprising: at least one of a laser irradiation device or a plasma processing device configured to receive a product 3D-printed by at least one 3D printer; and at least one controller configured to control at least one of the laser irradiation device or the plasma processing device to apply laser irradiation or plasma processing to the product.

[0323] Embodiment 18: The apparatus of Embodiment 7: wherein the product comprises one or more layers; and wherein the at least one controller is configured to control the laser irradiation device to apply laser irradiation to the surface or interior of at least one of the one or more layers.

[0324] Embodiment 19: The apparatus of Embodiment 17 or 18: wherein the one or more layers include an outer layer having a surface configured to contact the skin of a user of the product; and wherein the at least one controller is configured to control the laser irradiation device to apply laser irradiation by laser ablation, which forms a pattern on the surface of the outer layer to alter the sensation of the outer layer upon contact with the user's skin.

[0325] Embodiment 20: An apparatus of any one of embodiments 17-19: wherein the one or more layers include an outer layer having a surface configured to contact the skin of a user of the molded product; and wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to alter the interior of the outer layer. Specification 40 / 42 pages 44 CN 121100052 A

[0326] Embodiment 21: An apparatus of any one of embodiments 17-20: wherein the at least one controller is configured to control a laser radiation device to apply laser radiation by ablating at least a portion of the interior of the outer layer with a laser.

[0327] Embodiment 22: An apparatus of any one of embodiments 17-21: wherein the interior of the outer layer comprises at least one thermoplastic polymer and one or both of fibers or granules; andIn one embodiment, the at least one controller is configured to control a laser radiation device to remove at least a portion of the at least one thermoplastic polymer to enhance the effect on the skin of the user of the molded product.

[0328] Embodiment 23: An apparatus of any one of embodiments 17-22: wherein the one or more layers include an inner layer having a surface not configured to contact the skin of a user of the molded product; and wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to the inner layer of the molded product.

[0329] Embodiment 24: An apparatus of any one of embodiments 17-23: wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to the inner layer of the molded product to ablate at least a portion of the inner layer.

[0330] Embodiment 25: An apparatus of any one of embodiments 17-24: wherein the at least one controller is configured to control a laser radiation device to apply laser radiation to alter at least one of moisture management or drape of the molded product.

[0331] Embodiment 26: An apparatus of any one of Embodiments 17-25: wherein the molded product comprises one or more layers; and wherein the at least one controller is configured to control a plasma processing apparatus to apply plasma processing to the surface of at least one of the one or more layers.

[0332] Embodiment 27: A core / sheath structure comprising a molding material or a molded product formed from the molding material, the core / sheath structure comprising: a core having a linear shape and an outer peripheral surface and comprising at least one thermoplastic polymer; and a sheath at least partially covering the outer peripheral surface and comprising: (i) one or both of fibers or particles; and (ii) at least one of the following: a soluble substance; an antimicrobial substance; an ultraviolet protection substance; an odor management substance; or a moisture management substance.

[0333] Embodiment 28: The core / sheath structure of Embodiment 27: wherein the core / sheath structure is configured for 3D printing; and wherein the sheath comprises a water-soluble substance.

[0334] Embodiment 29: Core / sheath structure of Embodiment 27 or 28: wherein the water-soluble substance includes polyvinyl alcohol. Specification 42 / 42 pages 46 CN 121100052 A Figure 1 Figure 2 Specification Drawings 1 / 33 pages 47 CN 121100052 A Figure 3 Figure 4 Specification Drawings 2 / 33 pages 48 CN 121100052 A Figure 5 Figure 6 Specification Drawings 3 / 33 pages 49 CN 121100052 A Figure 7 Figure 8 Specification Drawings 4 / 33 pages 50 CN 121100052 A Figure 9 Figure 10 SpecificationFigure 5 / 33, page 51, CN 121100052 A, Figure 11, Figure 12; Figure 6 / 33, page 52, CN 121100052 A, Figure 13, Figure 14; Figure 7 / 33, page 53, CN 121100052 A, Figure 15, Figure 16; Figure 8 / 33, page 54, CN 121100052 A, Figure 17, Figure 18; Figure 9 / 33, page 55, CN 121100052 A, Figure 19; Figure 10 / 33, page 56, CN 121100052 A, Figure 20, Figure 21; Figure 11 / 33, page 57, CN 121100052 A, Figure 22; Figure 12 / 33, page 58, CN 121100052 A, Figure 23, Figure 28; Figure 13 / 33, page 59, CN 121100052 A, Figure 24. Figure 25 Appendix to the Instruction Manual, Page 14 / 33, 60 CN 121100052 A Figure 26 Appendix to the Instruction Manual, Page 15 / 33, 61 CN 121100052 A Figure 27A Appendix to the Instruction Manual, Page 16 / 33, 62 CN 121100052 A Figure 27B Appendix to the Instruction Manual, Page 17 / 33, 63 CN 121100052 A Appendix to the Instruction Manual, Page 18 / 33, 64 CN 121100052 A Appendix to the Instruction Manual, Page 19 / 33, 65 CN 121100052 A Appendix to the Instruction Manual, Page 20 / 33, 66 CN 121100052 A Appendix to the Instruction Manual, Page 21 / 33, 67 CN 121100052 A Appendix to the Instruction Manual, Page 22 / 33, 68 CN 121100052 A Appendix to the Instruction Manual, Page 23 / 33, 69 CN 121100052 A Instruction manual figures 24 / 33, page 70, CN 121100052 A; Instruction manual figures 25 / 33, page 71, CN 121100052 A; Instruction manual figures 26 / 33, page 72, CN 121100052 A; Instruction manual figures 27 / 33, page 73, CN 121100052 A; Figure 39, Figure 41; Instruction manual figures 28 / 33, page 74, CN 121100052 A; Figure 40; Instruction manual figures 29 / 33, page 75, CN 121100052 A; Figure 42, Figure 43; Instruction manual figures.Pages 30 / 33, 76 CN 121100052 A, Figures 44, 45, and 46 (Instruction Manual Drawings); Pages 31 / 33, 77 CN 121100052 A, Figure 47 (Instruction Manual Drawings); Pages 32 / 33, 78 CN 121100052 A, Figure 48 (Instruction Manual Drawings); Pages 33 / 33, 79 CN 121100052 A

Claims

1. A method for producing filaments, comprising: One or more extruders are used to extrude a first set of materials for the filament core and a second set of materials for the filament sheath, wherein the second set of materials includes at least one or both of fibers or granules; Using at least one die core portion and sheath portion to guide the first set of materials and the second set of materials extruded from the one or more extruders, respectively; and During or after using the core portion and the sheath portion of the at least one die head, a filament is formed by cooling a first set of materials and a second set of materials.

2. The method of claim 1, wherein, The one or more extruders include at least a first extruder for melting, mixing, and extruding a first group of materials and at least a second extruder for melting, mixing, and extruding a second group of materials; and The at least second extruder includes a twin-screw extruder.

3. The method of claim 2, wherein, The second group of materials includes at least one thermoplastic polymer and at least one or both of the fibers or particles.

4. The method of claim 3, wherein, The second group of materials also includes water-soluble polymers.

5. The method of claim 3, wherein, The diameter of the core portion of the at least one mold head is at least five times the thickness of the sheath portion of the at least one mold head.

6. A method for processing 3D printed products, the method comprising: Receive the finished 3D printed products; and After receiving the molded product, the molded product is subjected to at least one of laser radiation treatment or plasma treatment.

7. The method of claim 6, wherein, The molded product comprises one or more layers; and After the 3D printed product is formed, laser radiation is applied to the surface or interior of at least one of the one or more layers.

8. The method of claim 7, wherein, The one or more layers include an outer layer having a surface configured to contact the skin of a user of the molded product; and The application of laser radiation includes laser ablation, which forms a pattern on the surface of the outer layer to alter the sensation of the outer layer upon contact with the user's skin.

9. The method of claim 7, wherein, The one or more layers include an outer layer having a surface configured to contact the skin of a user of the molded product; and In this process, laser radiation is applied to alter the interior of the outer layer.

10. The method of claim 9, wherein, Applying laser radiation includes laser ablation of at least a portion of the outer layer's interior.

11. The method of claim 10, wherein, The outer layer comprises at least one thermoplastic polymer and one or both of fibers or granules; and Laser ablation includes removing at least a portion of the at least one thermoplastic polymer to enhance the effect on the skin of the user of the molded product.

12. The method of claim 7, wherein, The one or more layers include an inner layer having a surface not configured to contact the skin of a user of the molded product; and In this process, laser radiation is applied to the inner layer of the formed product.

13. The method of claim 12, wherein, Laser radiation is applied to the inner layer of the molded product to ablate at least a portion of the inner layer.

14. The method of claim 13, wherein, Ablation of at least a portion of the inner layer alters at least one of the moisture management or drape of the molded product.

15. The method of claim 14, wherein, The molded product comprises one or more layers; and After the 3D printed product is formed, a plasma treatment is applied to the surface of at least one of the one or more layers.

16. The method of claim 15, wherein, Plasma treatment cleans the surface of at least one of the one or more layers.

17. An apparatus configured to process 3D printed products, the apparatus comprising: At least one of a laser radiation device or a plasma processing device, configured to receive a shaped product 3D printed by at least one 3D printer; as well as At least one controller is configured to control at least one of the laser irradiation device or plasma treatment device to apply laser irradiation or plasma treatment to the shaped product.

18. The apparatus of claim 17, wherein, The molded product comprises one or more layers; and The at least one controller is configured to control a laser radiation device to apply laser radiation to the surface or interior of at least one of the one or more layers.

19. The apparatus of claim 18, wherein, The one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped product; and The at least one controller is configured to control a laser radiation device to apply laser radiation through laser ablation, which forms a pattern on the surface of the outer layer to alter the sensation of the outer layer upon contact with the user's skin.

20. The apparatus of claim 18, wherein, The one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped product; and The at least one controller is configured to control the laser radiation device to apply laser radiation to change the interior of the outer layer.

21. The apparatus of claim 20, wherein, The at least one controller is configured to control the laser radiation device to apply laser radiation by ablating at least a portion of the interior of the outer layer.

22. The apparatus of claim 21, wherein, The outer layer comprises at least one thermoplastic polymer and one or both of fibers or granules; and The at least one controller is configured to control a laser radiation device to remove at least a portion of the at least one thermoplastic polymer to enhance the effect on the skin of the user of the molded product.

23. The apparatus of claim 18, wherein, The one or more layers include an inner layer having a surface not configured to contact the skin of a user of the molded product; and The at least one controller is configured to control a laser radiation device to apply laser radiation to the inner layer of the molded product.

24. The apparatus of claim 23, wherein, The at least one controller is configured to control a laser radiation device to apply laser radiation to the inner layer of the molded product to ablate at least a portion of the inner layer.

25. The apparatus of claim 24, wherein, The at least one controller is configured to control a laser radiation device to apply laser radiation to alter at least one of the moisture management or drape of the shaped product.

26. The apparatus of claim 17, wherein, The molded product comprises one or more layers; and The at least one controller is configured to control a plasma processing device to apply plasma processing to the surface of at least one of the one or more layers.

27. A core / sheath structure comprising a molding material or a molded product formed from the molding material, the core / sheath structure comprising: A core having a linear shape and an outer peripheral surface and comprising at least one thermoplastic polymer; as well as A sheath that at least partially covers an outer peripheral surface and comprises: (i) one or both of fibers or particles; and (ii) at least one of the following: a soluble substance; an antimicrobial substance; an ultraviolet-protective substance; an odor-managing substance; or a moisture-managing substance.

28. The core / sheath structure of claim 27, wherein, The core / sheath structure is configured for 3D printing; and The sheath includes water-soluble substances.

29. The core / sheath structure of claim 28, wherein, Water-soluble substances include polyvinyl alcohol.

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