Electronically-activated, self-molding and re-shapeable load-bearing support structure system and methods for molding thereof

1. An electronically-activated, self-molding and re-shapeable load-bearing support structure system comprising:

a first composite structure including:

a first layer of a first thermally-responsive polymer having a first elastic modulus at a temperature below a glass transition temperature or a melting temperature and a second elastic modulus at a temperature greater than the glass transition temperature or the melting temperature, when the first elastic modulus is larger than the second elastic modulus by at least approximately 10 times larger to approximately 100 times larger;

one or more first heating elements positioned adjacent to the first layer on a first heating element side, the one or more first heating elements selected from one or more of carbon fibers, carbon fabric, conductive inks, metal mesh, metal film, metal wires, or flexible printed circuits, the one or more first heating elements forming a first heating zone;

a second layer of the first thermally-responsive polymer positioned adjacent to the one or more first heating elements on a second heating element side, the second layer having a first elastic modulus at a temperature below a glass transition temperature or a melting temperature and a second elastic modulus at a temperature greater than the glass transition temperature or the melting temperature, when the first elastic modulus is larger than the second elastic modulus by at least approximately 10 times larger to approximately 100 times larger;

a temperature sensor communicating with at least the first layer or the second layer of the first thermally-responsive polymer;

one or more electrical connectors electrically communicating with the one or more heating elements;

an electrical controller detachably connectable to at least one of the one or more electrical connectors of the composite for providing an electrical current to the one or more heating elements, the electrical controller electrically communicating with the temperature sensor when the electrical controller is connected to the one or more electrical connectors and for providing electricity to the heating element, the amount of electricity being determined by a measured temperature from the temperature sensor and a predetermined set temperature above the glass transition temperature or the melting temperature.

2. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , further comprising one or more second heating elements positioned between the first layer and the second layer of the first thermally-responsive polymer, the one or more second heating elements selected from one or more of carbon fibers, carbon fabric, conductive inks, metal mesh, metal film, metal wires, or flexible printed circuits, the one or more second heating elements forming a second heating zone, the second heating zone being independently controllable by the controller from the first heating zone.

3. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , wherein the composite structure further comprises a third layer of a second thermally-responsive polymer laterally adjacent to the first layer of the first thermally-responsive polymer having a third elastic modulus at a temperature below a glass transition temperature or a melting temperature and a fourth elastic modulus at a temperature greater than the glass transition temperature or the melting temperature, when the third elastic modulus is larger than the fourth elastic modulus by at least approximately 10 times larger to approximately 100 times larger and wherein the third layer of a second thermally-responsive polymer has a third elastic modulus that is greater than the first elastic modulus of the first thermally responsive polymer by at least approximately 10 times larger to approximately 100 times larger;

one or more third heating elements positioned adjacent to the third layer on a first heating element side, the one or more third heating elements selected from one or more of carbon fibers, carbon fabric, conductive inks, metal mesh, metal film, metal wires, or flexible printed circuits, the one or more third heating elements forming a third heating zone;

a fourth layer of the second thermally-responsive polymer positioned adjacent to the one or more third heating elements on a third heating element side, the fourth layer having a third elastic modulus at a temperature below a glass transition temperature or a melting temperature and a fourth elastic modulus at a temperature greater than the glass transition temperature or the melting temperature, when the third elastic modulus is larger than the fourth elastic modulus by at least approximately 10 times larger to approximately 100 times larger such that a region of the third and fourth layers of the second thermally-responsive material provides a region of greater stiffness or rigidity to the composite structure.

4. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 3 , wherein the second thermally-responsive polymer layer is selected from polyurethane block co-polymer, polylactic acid, polystyrene or polyacrylate.

5. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , wherein the temperature sensor includes a thermocouple, a resistance temperature detector, or a thermistor.

6. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , wherein the controller is configured to provide a temperature from 15° C. to 85° C.

7. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , wherein the controller includes a temperature feedback control circuit.

8. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 7 , wherein the temperature feedback control circuit is selected from a dynamic voltage control or a dynamic current control feedback circuit.

9. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , wherein the controller includes a feedback control circuit.

10. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 wherein the first thermally-responsive polymer layer includes a thermally conductive filler in an amount up to 85 weight %.

11. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 10 , wherein the thermally-conductive filler is selected from one or more of boron nitride (BN), silica coated aluminum nitride (SCAN), metal oxides, SiO 2 , or non-oxide ceramic powders.

12. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , wherein the first thermally-responsive polymer layer is selected from a polyurethane block co-polymer, polylactic acid, polystyrene or polyacrylate.

13. The electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 wherein the elastic modulus of the first thermally-responsive polymer is between approximately 9×10 8 Pa to approximately 5×10 9 Pa at temperatures below the glass transition temperature or the melting temperature, and is from approximately 1×10 6 Pa to approximately 5×10 7 Pa at temperatures above the glass transition temperature or the melting temperature.

14. A method of molding the electronically-activated, self-molding and re-shapeable load-bearing support structure system according to claim 1 , comprising:

heating the first and second layers of first thermally-responsive polymer to a temperature above a glass transition temperature or a melting temperature of the first thermally-responsive polymer;

positioning the first and second layers of first thermally-responsive polymer around a first shape;

cooling the first and second layers of first thermally-responsive polymer to retain the first shape.

15. The method of molding according to claim 14 , wherein the shape is a human or animal body part.

16. The method of molding according to claim 14 , further comprising:

reheating the first and second layers of first thermally-responsive polymer to a temperature above a glass transition temperature or a melting temperature of the first thermally-responsive polymer;

reshaping the first and second layers of first thermally-responsive polymer into a second shape;

cooling the first and second layers of first thermally-responsive polymer to retain the second shape.

17. The method of molding according to claim 16 , wherein the second shape is different from the first shape.