Flexible housing structure for performance elements

Abstract

Aspects of the disclosure relate to a flexible shell structure. The flexible shell structure includes a plurality of rigid support bands collectively defining a three-dimensional shape of at least one portion of a character form. The flexible shell structure further includes at least one coupling member configured to couple two or more of the plurality of rigid support bands. The at least one coupling member enables the flexible shell structure to bend when a first force is applied to the flexible shell structure in a first direction and enables the flexible shell structure to resist bending when a second force is applied to the flexible shell structure in a second direction.

Description

[0001] Cross-reference to (one or more) related applications

[0002] This application claims priority and benefit to U.S. Utility Application Serial No. 17 / 543,584, filed December 6, 2021, entitled "Flexible Shell Structure for Show Elements," which in turn claims priority and benefit to U.S. Provisional Application Serial No. 63 / 122,454, filed December 7, 2020, also entitled "Flexible Shell Structure for Show Elements," the entire contents of which are hereby incorporated herein by reference. Technical Field

[0003] The technology discussed below generally relates to a shell structure, and more specifically to a flexible shell structure for performance elements. Background Technology

[0004] Performance elements, such as animated characters (e.g., robots), can be incorporated into shell structures to achieve a desired aesthetic appearance. For example, rigid shell structures formed similarly to parts of a character (e.g., a human chest or torso, parts of a fictional creature, etc.) can be used to encapsulate hardware that controls the movement of the performance element (e.g., electromechanical actuators, electronics, cables, etc.). The size and shape of these shell structures are typically defined by the aesthetic requirements of the performance element. As a result, these shell structures may often limit the mechanical properties of the performance element (e.g., range of motion). Summary of the Invention

[0005] The following is a brief overview of one or more aspects of this disclosure in order to provide a basic understanding of such aspects. This overview is not a comprehensive summary of all the intended features of this disclosure, and is neither intended to identify the principal or key elements of all aspects of this disclosure, nor to depict the scope of any or all aspects of this disclosure. Its sole purpose is to present some concepts of one or more aspects of this disclosure in a concise form as a prelude to the more detailed description that follows.

[0006] This disclosure relates to a flexible shell structure. The flexible shell structure includes a plurality of rigid support bands that collectively define a three-dimensional shape of at least one portion of the form. The flexible shell structure further includes at least one coupling member configured to couple two or more of the plurality of rigid support bands. The at least one coupling member enables the flexible shell structure to bend when a first force is applied to it in a first direction, and enables it to resist bending when a second force is applied to it in a second direction.

[0007] In one example, a method for generating a flexible shell structure is disclosed. The method includes generating a plurality of rigid support strips of a three-dimensional shape that collectively defines at least one portion of a role-like form. The method further includes coupling two or more of the plurality of rigid support strips to at least one coupling member. The at least one coupling member enables the flexible shell structure to bend when a first force is applied to the flexible shell structure along a first direction, and enables the flexible shell structure to resist bending when a second force is applied to the flexible shell structure along a second direction. Attached Figure Description

[0008] Figure 1 (including) Figures 1A to 1D This shows an example of the range of motion of the articulated arm of an animated character.

[0009] Figure 2 (including) Figures 2A to 2D (This is another example showing the range of motion of the articulated arm of an animated character.)

[0010] Figure 3 (including) Figures 3A to 3D (This is another example showing the range of motion of the articulated arm of an animated character.)

[0011] Figure 4 The illustration shows flexible shell structures according to various aspects of this disclosure.

[0012] Figure 5 The illustration shows detailed views of rigid support strips and coupling members in flexible shell structures according to various aspects of this disclosure.

[0013] Figure 6 A cross-section of the coupling member according to various aspects of this disclosure is shown.

[0014] Figure 7 A side view of a rigid support strip according to various aspects of this disclosure is shown.

[0015] Figure 8 A side view of a rigid support strip according to various aspects of this disclosure is shown.

[0016] Figure 9 This shows portions of the padding material coupled to the rigid support strip according to various aspects of this disclosure.

[0017] Figure 10 Flexible shell structures according to various aspects of this disclosure are shown.

[0018] Figure 11 It is a flowchart based on various aspects of this disclosure. Detailed Implementation

[0019] The detailed description set forth below in conjunction with the accompanying drawings is intended as a description of various configurations and is not intended to represent the only configuration in which the concepts described herein can be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the various concepts. However, it will be apparent to those skilled in the art that these concepts can be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form to avoid obscuring such concepts. While aspects and embodiments are described in this application as examples by illustration, those skilled in the art will understand that additional implementations and uses can occur in many different arrangements and situations. The innovations described herein can be implemented across many different platform types, devices, systems, shapes, sizes, and / or packaging arrangements.

[0020] Figure 1 (including) Figures 1A to 1D The illustration depicts animated character 100 (also known as a robot), in which... Figure 1A Showing the front view of the animated character 100, Figure 1B Showing a side view of the animated character 100, Figure 1C Showing a front perspective view of the animated character 100, and Figure 1D The rear perspective view of the animated character 100 is shown. The animated character 100 has hinged arms 102, 104 and hinged legs 106, 108. Figure 1A As shown, the articulated arms 102 and 104 can be controlled by corresponding electromechanical actuators 110 and 112, and the articulated legs 106 and 108 can be controlled by corresponding electromechanical actuators 114 and 116.

[0021] In some examples, the animated character 100 may be configured for use as a performance element or for other entertainment purposes. As used herein, the term "performance element" may refer to a tangible character, tangible object, tangible device, or tangible system made or produced for theatrical or entertainment purposes. For example, the animated character 100 may be configured as a character for live performances, attractions (e.g., rides or exhibits in a theme park), television performances, feature films, and / or other suitable entertainment applications. Thus, and as... Figure 1AAs shown, the animated character 100 may include one or more solid shell structures (e.g., solid shell structures 118, 120, 122, 124) that provide the animated character with a desired aesthetic appearance. In some examples, each of the solid shell structures may be formed using a rigid material (e.g., plastic, 3D printed parts, or other suitable materials) and may have a character-like shape or a portion of a character-like form. In some examples, each of the solid shell structures may be covered with a flexible material (e.g., silicone, polyurethane, foam, rubber, and / or other suitable materials) to give the animated character 100 a realistic outer skin appearance.

[0022] In other examples, performance elements may not be animated (e.g., they may not be actuated by electromechanical actuators). For example, a performance element may be a static prop, such as a bumper of a vehicle to be used in a theatrical production. In this example, the flexible shell described herein may be implemented in the shape of a bumper. Thus, when a live actor (e.g., a live actor playing a part in a superhero role with immense strength) pushes against the bumper, the bumper may shift in at least one direction to give the illusion that the bumper has deformed.

[0023] As used herein, the term "character form" can refer to the appearance, appearance, and / or aesthetic qualities of a particular character. In some examples, a character can be a fictional character, such as a fictional person, animal, or creature. In other examples, a character can be an anthropomorphic object (e.g., a talking tree or lamp with animated arms and / or legs). In yet another example, a character can be a non-fictional character, such as a person (e.g., a historical figure) or a real animal (e.g., a horse, dog, etc.).

[0024] One or more of the solid shell structures of the animated character 100 can be used as structures to support a covering. In some examples, the covering can be a stage costume, uniform, suit, etc., and can include one or more garments, such as shirts, skirts, coats, dresses, and / or other suitable clothing items. For example, solid shell structure 118 can support the shirt of the animated character 100, wherein the shape of solid shell structure 118 simulates the presence of a human torso beneath the shirt.

[0025] Each of the articulated arms 102, 104 and articulated legs 106, 108 of the animated character 100 can have a range of motion. For example, as Figure 1A As shown, the articulated arm 104 of the animated character 100 can have a lateral range of motion defined by a lowest position 126 and a highest position 130. Therefore, in this example, the articulated arm 104 can move laterally to an intermediate lateral position (e.g., intermediate lateral position 128) between the lowest position 126 and the highest position 130. Figure 1AAs shown, the solid housing structure 118 may include hinge gap features at or near the electromechanical actuator of each hinged arm, such as hinge gap feature 132 that exposes the electromechanical actuator 112 of the hinged arm 104. Hinge gap feature 132 allows the hinged arm 104 to be raised or lowered without being obstructed by the solid housing structure 118.

[0026] Figure 2 (including) Figures 2A to 2D (This shows another example of the range of motion of the articulated arm 104.) Figure 2A Showing the front view of the animated character 100, Figure 2B Showing a side view of the animated character 100, Figure 2C Showing a front perspective view of the animated character 100, and Figure 2D This shows a rear perspective view of the animated character 100. (As shown) Figure 2A and Figure 2B As shown, the electromechanical actuator 112 can rotate the hinged arm 104 of the animated character 100. For example, the hinged arm 104 can be moved to a lowest position 126, a forward horizontal position 216, a highest position 130, a rear horizontal position 220, or an intermediate position (e.g., intermediate positions 218, 222). Figure 2A As shown, the hinge gap feature 132 allows the hinged arm 104 to rotate without being obstructed by the solid housing structure 118.

[0027] Figure 3 (including) Figures 3A to 3D (This shows another example of the range of motion of the articulated arm 104.) Figure 3A Showing the front view of the animated character 100, Figure 3B Showing a side view of the animated character 100, Figure 3C Showing a front perspective view of the animated character 100, and Figure 3D This shows a rear perspective view of the animated character 100. (As shown) Figure 3A As shown, the articulated arm 104 of the animated figure 100 can move side-to-side. For example, the articulated arm 104 can move from a first position 320 to a second position 322. As another example, the articulated arm 104 can move from a third position 324 to a fourth position 326. The solid housing structure 118 may impede the movement of the articulated arm 104 (e.g., when the articulated arm 104 moves to the second position 322 or the fourth position 326) and may limit the range of motion of the articulated arm 104 (e.g., the range of side-to-side movement). Reference Figure 3CIt should be noted that when the hinged arm 104 moves to the second position 322 or the fourth position 326, the hinge gap feature 132 may not provide sufficient clearance for the hinged arm 104. In some cases, the hinged arm 104 may collide with the solid housing structure 118 (e.g., in region 328) and may damage the solid housing structure 118.

[0028] Figure 4 The illustration shows a flexible shell structure 400 according to various aspects of this disclosure. In some examples, and as described herein, the flexible shell structure 400 may be part of a performance element or may be configured for other entertainment purposes. For example, at least one portion of the flexible shell structure 400 may be coupled or attached to a performance element structure (e.g., the flexible shell structure 400 may be rigidly mounted on region 119 of the animated character 100 in FIG. 1). In some examples, the performance element structure may be an animated character, a robot character, a doll, a walking character, an interactive character, a theatrical prop, a static prop, or an animated prop. In one example, the flexible shell structure 400 may replace the solid shell structure 118 described herein.

[0029] In some examples, the flexible shell structure 400 may be covered with a flexible material (e.g., silicone, polyurethane, foam, rubber, and / or other suitable material) that simulates the skin used for the character form. For example, the flexible material may have the color and texture of human skin to achieve a realistic appearance of a human torso. In other examples, if the aspects described herein are used to configure the flexible shell structure for an animal character form, the flexible material may have a color and texture appropriate for the intended animal (e.g., fur-like).

[0030] The flexible shell structure 400 can be used as a structure to support a covering. In some aspects of this disclosure, the covering may include flexible materials such as rubber, silicone, vinyl, polyurethane, neoprene, foam, fabric, and / or textiles. In some examples, the covering may be stage costumes (e.g., at least one item of clothing) as described herein. For example, the flexible shell structure 400 may support the shirt of the animated character 100, wherein the shape of the flexible shell structure 400 simulates the presence of a human torso beneath the shirt.

[0031] like Figure 4As shown, the flexible shell structure 400 may include several rigid support bands, such as rigid support bands 401, 402, 404, 406, and 408. In some examples, one or more of the rigid support bands may be formed using a rigid and relatively lightweight material, such as plastic or other suitable material. In some examples, one or more of the rigid support bands may be formed using a printer (e.g., a 3D printer) for producing three-dimensional (3D) parts.

[0032] In some aspects of this disclosure, the rigid support strip can be designed to collectively define the three-dimensional shape of a character form or a portion thereof. For example, in Figure 4 In some implementations, rigid support bands (e.g., rigid support bands 401, 402, 404, 406, 408) define the three-dimensional shape of the human torso. In some example implementations, the three-dimensional shape may be a different part of a human character, a part of an animal or biological character, or a part of an object character. For example, the three-dimensional shape may be a body, legs, or tail of an animal character.

[0033] like Figure 4 As shown, rigid support bands can be coupled to one or more coupling members. For example, rigid support bands 404 and 406 can be coupled to coupling member 440 (e.g., portion 444 of coupling member 440) and coupling member 448. As another example, rigid support bands 406 and 408 can be coupled to coupling member 428 (e.g., portion 430 of coupling member 428), coupling member 440 (e.g., portion 446 of coupling member 440), and coupling members 420, 422, 424, and 426. At least some of the coupling members are shaped to allow the flexible shell structure 400 to bend when a first force is applied to the flexible shell structure 400 in a first direction (e.g., horizontal direction) and to resist bending when a second force is applied to the flexible shell structure 400 in a second direction (e.g., vertical direction).

[0034] In some aspects of this disclosure, at least a portion of the flexible shell structure 400 may be configured in a movable joint of the performance element structure (e.g., Figure 1A The flexible shell structure 400 is located at or near the shoulder joint 105 of the hinged arm 104 shown herein, wherein the flexible shell structure 400 is configured to bend in response to movement of the movable joint (e.g., when the hinged arm 104 rotates about the shoulder joint 105 and comes into contact with the flexible shell structure 400). In some aspects of this disclosure, features of the flexible shell structure 400 as described herein can be used to form flexible shell structures for simulating shoulder joints (e.g., to simulate the appearance of shoulder muscles), elbow joints, wrist joints, hip joints, ankle joints, and / or other suitable joints of the animated character 100.

[0035] For example, coupling members (e.g., coupling members 420, 422, 424, 426, 428, 440) can be formed of rigid or partially rigid materials (e.g., plastic, 3D printed parts). In some aspects of this disclosure, the coupling member can have a cylindrical or tubular shape and can include one or more twists, bends, curves, and / or other suitable features to enable bending. In some examples, the overall appearance of the coupling member can be described as a wave shape, a coiled shape, or a spring shape. The coupling member can be configured to bend (e.g., bend or deflect) in response to a first force (e.g., force F1 432 or force F3 436) and resist bending in response to a second force (e.g., force F2 434). Figure 4 As shown, the direction of the first force (e.g., force F1432 or force F3436) may be approximately perpendicular to the direction of the second force (e.g., force F2434). It should be understood that the coupling members of the flexible shell structure 400 allow the flexible shell structure 400 to return to its original shape when the first force (e.g., force F1432 or force F3436) is no longer applied.

[0036] In some aspects of this disclosure, the flexibility of the flexible shell structure 400 may be based on the length of each coupling member and / or the thickness of each coupling member. This reference... Figure 5 and Figure 6 It is described in detail. Figure 5 Detailed views of rigid support bands 404 and 406 and coupling member 448 are shown. Figure 5 As shown, the rigid support strip 404 may include a front surface 514, a first side surface 516, and a second side surface 518. The rigid support strip 406 may include a front surface 520, a first side surface 522, and a second side surface 524. Figure 5 As further shown, the first end of the coupling member 448 can be coupled to the second side surface 518 and the second end of the coupling member 448 can be coupled to the first side surface 522. Figure 5 In one example, the flexibility of the flexible shell structure 400 can be increased as the length 506 of the coupling member 448 increases. In other examples, if the application requires the flexible shell structure 400 to be more rigid (e.g., for improved stability when supporting heavy stage costumes), the length 506 of the coupling member 448 can be reduced.

[0037] As another example, the flexibility of the flexible shell structure 400 can increase as the thickness of the coupling member 448 decreases. For example, Figure 6 Show Figure 5The cross-section of the coupling member 448 along line 502. In one example, the flexibility of the flexible shell structure 400 can be increased as the diameter 622 of the coupling member 448 decreases. In other examples, if the application requires a more rigid flexible shell structure 400, the diameter 622 of the coupling member 448 can be increased. In some aspects of this disclosure, the thickness of the coupling member 448 can be varied along the length 506 of the coupling member 448.

[0038] In some aspects of this disclosure, the width of the rigid support strip may vary at different portions of the rigid support strip. For example, the rigid support strip 404 may have a first width 504 and a second width 512, wherein the second width 512 is greater than the first width 504. In some aspects of this disclosure, portions of the support strip may be made thicker to increase the stiffness and / or strength of the rigid support strip.

[0039] In some aspects of this disclosure, the increased thickness of the rigid support strip can vary at different portions of the rigid support strip. For example, Figure 7 It is shown (for example, in the example from) Figure 5 (When viewing the rigid support strip 404 in the direction of arrow 510) Side view of the rigid support strip 404. (See also:) Figure 7 As shown, the rigid support strip 404 may have a first thickness 716 and a second thickness 718, wherein the second thickness 718 is greater than the first thickness 716. In some aspects of this disclosure, portions of the rigid support strip may be made thicker to increase the stiffness and / or strength of the rigid support strip.

[0040] In some aspects of this disclosure, the rigid support strip can have a uniform thickness. For example, Figure 8 It is shown (for example, in the example from) Figure 5 (When observing the rigid support strip 406 in the direction of arrow 526) Side view of the rigid support strip 406. (See also:) Figure 8 As shown, the rigid support strip 406 may have a thickness of 818.

[0041] In some aspects of this disclosure, the rigid support strips described herein may be spaced apart by one or more spacing distances. In these aspects of this disclosure, larger spacing distances can increase the flexibility of the flexible shell structure 400, while shorter spacing distances can decrease the flexibility of the flexible shell structure 400. For example, refer to... Figure 5The rigid support bands 404 and 406 can be separated by a separation distance 508. In this example, the flexibility of the flexible shell structure 400 can increase as the separation distance 508 increases. In other examples, the separation distance 508 can be reduced if the application requires greater rigidity of the flexible shell structure 400. In some aspects of this disclosure, at least two of the separation distances can be different. For example, the rigid support bands closer to the center of the flexible shell structure 400 (e.g., rigid support bands 406 and 408) can have a shorter separation distance than the rigid support bands closer to the ends of the flexible shell structure 400.

[0042] In some aspects of this disclosure, the flexible shell structure 400 may include padding material (also referred to as backing material) coupled to at least two of the rigid support strips. The padding material may span the gaps between the rigid support strips to provide additional support and / or mechanical protection to the flexible shell structure 400. In one example, the padding material may be coupled to a first front surface of the first rigid support strip (e.g., front surface 514 of rigid support strip 404) and a second front surface of the second rigid support strip (e.g., front surface 520 of rigid support strip 406). In another example, the padding material may be coupled to a side surface of the first rigid support strip (e.g., second side surface 518 of rigid support strip 404) and a side surface of the second rigid support strip (e.g., first side surface 522 of rigid support strip 406). In yet another example, the padding material may be coupled to a rear surface of the first rigid support strip (e.g., rear surface 720 of rigid support strip 404) and a rear surface of the second rigid support strip (e.g., rear surface 820 of rigid support strip 406).

[0043] In some configurations, padding material can control the offset of the rigid support bands (e.g., limit the bending of the rigid support bands). This allows the flexible shell structure 400 to support a larger weight (e.g., heavy stage costumes) while reducing distortion of its original shape. For example, Figure 9 A portion of the padding material 902 coupled to rigid support strips 404 and 406 is shown. In some examples, the padding material 902 may be coupled to... Figure 4 All rigid support bands of the flexible shell structure 400 shown herein. For example, the padding material may be a natural fabric (e.g., cotton fabric), a synthetic fabric (e.g., polyester fabric), a flexible plastic sheet, or a combination thereof.

[0044] In some aspects of this disclosure, there may be a correlation between the respective dimensions and shapes of each rigid support band (e.g., rigid support bands 401, 402, 404, 406, 408) and the respective dimensions and shapes of each coupling member (e.g., coupling members 420, 422, 424, 426, 428, 440). For example, the width and thickness of each rigid support band and the diameter of each coupling member may be increased to increase the overall strength of the flexible shell structure while reducing its flexibility. However, some configurations of the flexible shell structure may not be subject to the correlations described above. For example, to suit the strength and flexibility requirements of a given application, the diameter of one or more coupling members may be greater than the width and / or thickness of one or more of the rigid support bands.

[0045] In some aspects of this disclosure, different regions of the flexible shell structure 400 (or different regions of the flexible shell structure 1002) may have different amounts of flexibility. For example, refer to Figure 4 The flexible shell structure 400, in which rigid support bands 401 are included, can have a greater degree of flexibility at its end regions compared to the central region of the flexible shell structure 400 including rigid support bands 406, 408. This configuration allows the flexible shell structure 400 to provide greater flexibility near the movable joints of the animated character or doll, while providing an appropriate amount of stiffness (e.g., strength) to support the stage costume of the animated character or doll.

[0046] Figure 10 A flexible shell structure 1002 according to various aspects of this disclosure is shown. For example... Figure 10 As shown, the flexible shell structure 1002 may include several rigid support bands, such as rigid support bands 1004, 1006, 1008, 1010, and 1012. In some examples, one or more of the rigid support bands may be formed using a rigid and relatively lightweight material as described previously in the reference to the flexible shell structure 400. Figure 10 In the described aspects, one or more of the rigid support strips (e.g., rigid support strips 1004, 1006, 1008, 1010, 1012) may have a curved shape.

[0047] exist Figure 10 In some example embodiments, rigid support bands with curved shapes (e.g., rigid support bands 1004, 1006, 1008, 1010, 1012) define the three-dimensional shape of the human torso. In some example embodiments, the three-dimensional shape may be a different part of a human character, a part of an animal or biological character, or a part of an object character. For example, the three-dimensional shape may be a body, legs, or tail of an animal character.

[0048] The rigid support bands of the flexible shell structure 1002 can be coupled to one or more coupling members (such as coupling members 1014, 1016). The one or more coupling members can allow at least some of the rigid support bands (e.g., rigid support bands 1004, 1006, 1008, 1010, and / or 1012) to bend in response to a first force (e.g., force F1 1022 resulting from the movement of the hinged arm 1018 toward the flexible shell structure 1002) and to resist bending in response to a second force (e.g., force F2 1024). Figure 10 As shown, the direction of the first force (e.g., force F1 1022) may be approximately perpendicular to the direction of the second force (e.g., force F2 1024). It should be understood that the coupling members of the flexible shell structure 1002 allow the flexible shell structure 1002 to return to its original shape when the first force (e.g., force F1 1022) is no longer applied.

[0049] For example, refer to Figure 10 The region of the flexible shell structure 1002 including rigid support bands 1004 and 1006 can have a greater amount of flexibility than the region including rigid support bands 1010 and 1012. In some aspects, the different amounts of flexibility can be related to the corresponding shape of each of the multiple rigid support bands. For example, rigid support bands 1010 and 1012 can be shorter, wider, and have a smaller curvature than rigid support bands 1002 and 1004. In this example, the center of the flexible shell structure 1002 (e.g., the region including rigid support bands 1010 and 1012) can have less flexibility and greater strength than the ends of the flexible shell structure 1002 (e.g., the regions including rigid support bands 1004 and 1006).

[0050] exist Figure 4-10 In the aspects previously described, the flexibility of the described flexible shell structure (e.g., flexible shell structure 400, 1002) can improve the range of motion of animated figures, dolls, or other objects. For example, if flexible shell structure 400 (or flexible shell structure 1002) replaces solid shell structure 118 and is coupled to... Figure 3C As shown in the animated figure 100, the flexible shell structure 400 can bend when the hinged arm 104 moves to the second position 322 or the fourth position 326. This allows for a larger range of movement of the hinged arm 104 compared to the range of movement allowed by the solid shell structure 118. Furthermore, the flexibility of the flexible shell structure 400 can prevent damage to the flexible shell structure 400 when the hinged arm 104 comes into contact with it.

[0051] It should be noted that the flexible shell structure 400 (or flexible shell structure 1002) is configured to withstand forces applied in one direction (e.g., from the hinged arm 104 moving to the second position 322 or the fourth position 326). Figure 4 When the force F3 436 is applied, the body bends and another force is applied in a different direction (e.g., caused by the weight of the stage costume and applied in a direction perpendicular to force F3 436). Figure 4 The flexible shell structure 400 is designed to resist bending when subjected to a force F2 434. Therefore, the flexible shell structure 400 can be bent to improve the range of motion (e.g., for animated characters or dolls) while providing sufficient stiffness to support the covering (e.g., relatively heavy stage costumes or other suitable coverings).

[0052] Figure 11 This is a flowchart illustrating an exemplary process 1100 for generating a flexible shell structure (e.g., flexible shell structure 400 or flexible shell structure 1002) according to aspects of this disclosure. As described below, some or all of the illustrated features may be omitted in certain embodiments within the scope of this disclosure, and some illustrated features may not be necessary for implementations of all embodiments. Process 1100 can be performed by any suitable device or means for performing the functions or algorithms described below. In some examples, the device may be a 3D printing apparatus.

[0053] At box 1102, the device generates a plurality of rigid support bands (e.g., rigid support bands 401, 402, 404, 406, 408 or rigid support bands 1004, 1006, 1008, 1010, 1012) that collectively define at least one portion of the character form. In some examples, the character form may be based on a human character form, an animal character form, a fictional creature character form, or an object character form (e.g., an anthropomorphic object as described herein).

[0054] At frame 1104, the device couples two or more of a plurality of rigid support strips to at least one coupling member (e.g., coupling member 448 or coupling members 1014, 1016). The at least one coupling member enables the flexible shell structure to bend when a first force is applied to it in a first direction, and enables it to resist bending when a second force is applied to it in a second direction. In some examples, the first direction may be approximately perpendicular to the second direction. In some examples, the flexibility of the flexible shell structure may be based on at least one of the length or thickness of the at least one coupling member.

[0055] In this disclosure, the term "exemplary" is used to mean "serving as an example, instance, or illustration." Any implementation or aspect described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other aspects of this disclosure. Similarly, the term "aspect" does not require that all aspects of this disclosure include the features, advantages, or patterns of the operations discussed. The term "coupling" is used herein to refer to direct or indirect coupling between two objects. For example, if object A physically touches object B, and object B touches object C, then object A and object C can still be considered coupled to each other—even if they do not directly physically touch each other. For example, a first object can be coupled to a second object even if the first object never directly physically contacts the second object.

[0056] One or more of the components, steps, features, and / or functions illustrated in Figures 1-11 can be rearranged and / or combined into a single component, step, feature, or function, or implemented in several components, steps, or functions. Additional elements, components, steps, and / or functions can also be added without departing from the novel features disclosed herein. The devices, apparatuses, and / or components illustrated in Figures 1-11 can be configured to perform one or more of the methods, features, or steps described herein. The novel algorithms described herein can also be effectively implemented in software and / or embedded in hardware.

[0057] It should be understood that the specific order or hierarchy of steps in the disclosed method is a diagram of an exemplary process. Based on design preferences, it is understood that the specific order or hierarchy of steps in the method can be rearranged. The appended method claims present the elements of various steps in a sample order and are not intended to be limited to the specific order or hierarchy presented, unless specifically stated herein.

[0058] The preceding description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will readily be apparent to those skilled in the art, and the general principles described herein can be applied to other aspects. Therefore, the claims are not intended to be limited to the aspects shown herein, but rather to be consistent with the entire scope of the language used in the claims, and references to elements in the singular form in the claims are not intended to mean “one and only one” (unless specifically stated otherwise), but rather “one or more.” Unless otherwise specifically stated, the term “some” means one or more. Statements relating to “at least one of” a series of items refer to any combination of these items, including individual elements. As an example, “at least one of a, b, or c” is intended to cover: a; b; c; a and b; a and c; b and c; and a, b, and c. All structural and functional equivalents of the elements throughout the various aspects described in this disclosure that are known to or later become known to those skilled in the art are hereby incorporated by reference and are intended to be covered by the claims. Furthermore, nothing disclosed herein is intended to be offered to the public, whether such disclosure is explicitly stated in the claims.

Claims

1. A flexible shell structure, comprising: Multiple rigid support bands, which together define the three-dimensional shape of at least one part of the character form; as well as At least one coupling member configured to couple two or more of the plurality of rigid support strips, wherein a first end of the at least one coupling member is coupled to a side surface of one of the two or more rigid support strips and a second end of the at least one coupling member is coupled to a side surface of another of the two or more rigid support strips. The at least one coupling member enables the flexible shell structure to bend when a first force is applied to the flexible shell structure in a first direction, and enables the flexible shell structure to resist bending when a second force is applied to the flexible shell structure in a second direction.

2. The flexible shell structure according to claim 1, wherein at least one portion of the flexible shell structure is attached to the performance element structure.

3. The flexible shell structure according to claim 2, wherein the performance element structure includes animated characters, robot characters, dolls, characters that walk around, interactive characters, theatrical props, static props, or animated props.

4. The flexible shell structure of claim 2, wherein at least a portion of the flexible shell structure is disposed at or near a movable joint of the performance element structure, and wherein the flexible shell structure is configured to bend in response to movement of the movable joint.

5. The flexible shell structure according to claim 1, wherein the first direction is approximately perpendicular to the second direction.

6. The flexible shell structure according to claim 1, wherein the flexibility of the flexible shell structure is based on at least one of the length or thickness of the at least one coupling member.

7. The flexible shell structure of claim 6, wherein the plurality of rigid support bands are spaced apart by a separation distance, and wherein the flexibility of the flexible shell structure is further based on the separation distance.

8. The flexible shell structure according to claim 7, wherein at least two of the separation distances are different.

9. The flexible shell structure according to claim 1, wherein at least one of the plurality of rigid support strips has at least a first width and a second width.

10. The flexible shell structure according to claim 1, wherein at least one of the plurality of rigid support strips has at least a first thickness and a second thickness.

11. The flexible shell structure according to claim 1, wherein the stiffness of each of the plurality of rigid support strips is based on at least one of the width or thickness of each of the plurality of rigid support strips.

12. The flexible shell structure according to claim 1, wherein different regions of the flexible shell structure have different amounts of flexibility, and wherein the different amounts of flexibility are related to the corresponding shape of each of the plurality of rigid support strips.

13. The flexible shell structure according to claim 1, wherein at least one of the plurality of rigid support strips has a curved shape.

14. The flexible shell structure according to claim 1, further comprising padding material coupled to at least two of the plurality of rigid support strips.

15. The flexible shell structure of claim 14, wherein the at least two rigid support bands comprise a first rigid support band and a second rigid support band, and wherein the padding material is coupled to... The first rear surface of the first rigid support strip and the second rear surface of the second rigid support strip, The first front surface of the first rigid support strip and the second front surface of the second rigid support strip, or The first side surface of the first rigid support strip and the second side surface of the second rigid support strip.

16. The flexible shell structure of claim 14, wherein the padding material comprises at least one of natural fabric, synthetic fabric or flexible plastic sheet.

17. The flexible shell structure according to claim 1, wherein the flexible shell structure is part of the performance element.

18. The flexible shell structure according to claim 17, wherein the performance element includes a tangible image, a tangible object, a tangible device, or a tangible system.

19. The flexible shell structure according to claim 1, wherein the role form includes a human role form, an animal or biological role form, or an object role form.

20. The flexible shell structure of claim 1, wherein the flexible shell structure is covered with a flexible material to simulate an outer skin for the character form, the flexible material comprising at least one of silicone, polyurethane, foam, or rubber materials.

21. The flexible shell structure of claim 1, wherein the flexible shell structure simulates the presence of the role form beneath the cover.

22. The flexible shell structure of claim 21, wherein the covering comprises at least one item of clothing.

23. The flexible shell structure of claim 21, wherein the covering comprises a flexible material, the flexible material comprising at least one of rubber material, silicone material, vinyl material, polyurethane material, neoprene rubber material, foam material, fabric or textile.

24. The flexible shell structure according to claim 1, further comprising: At least one other coupling member configured to couple two or more of the plurality of rigid support strips. Wherein, at least one other coupling member is coupled to the end of the first rigid support belt and the end of the second rigid support belt among the two or more rigid support belts.

25. A method for generating a flexible shell structure, comprising: Multiple rigid support bands are generated, which together define the three-dimensional shape of at least one part of the character form; as well as Two or more of the plurality of rigid support strips are coupled to at least one coupling member, wherein a first end of the at least one coupling member is coupled to a side surface of one of the two or more rigid support strips and a second end of the at least one coupling member is coupled to a side surface of another of the two or more rigid support strips. The at least one coupling member enables the flexible shell structure to bend when a first force is applied to the flexible shell structure in a first direction, and enables the flexible shell structure to resist bending when a second force is applied to the flexible shell structure in a second direction.

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