Hierarchical branched micro-truss structure and methods of manufacturing the same

• US 10,400,842 B1
• Filed: 07/14/2017
• Issued: 09/03/2019
• Est. Priority Date: 02/13/2014
• Status: Active Grant

• Current Assignee: HRL Laboratories LLC (The Boeing Co.)
• Original Assignee: HRL Laboratories LLC (The Boeing Co.)
• Inventors: Schaedler, Tobias A., Yang, Sophia S., Jiang, Jie, Eckel, Zak C., Roper, Christopher S.
• Primary Examiner(s): Kianni, Kaveh C
• Assistant Examiner(s): Lam, Hung Q
• Application Number:
  US15/650,547
• Time in Patent Office: 781 Days
• Field of Search: 385 9, 385 14, 385 45, 385 46, 385 95, 385120, 385125, 385129-132
• CPC Class Codes: F16F 7/121 the members having a cellular, e.g. honeycomb, structure
• CPC Class Codes: F16F 7/125 Units with a telescopic-like action as one member moves into, or out of a second member F16F7/124, F16F7/127, F16F7/128 take precedence
• CPC Class Codes: G02B 6/02033 Core or cladding made from organic material, e.g. polymeric material G02B1/04 takes precedence
• CPC Class Codes: G02B 6/12002 Three-dimensional structures
• CPC Class Codes: G02B 6/138 by using polymerisation
• CPC Class Codes: G03F 7/0005 Production of optical devices or components in so far as characterised by the lithographic processes or materials used therefor
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/30 Imagewise removal using liquid means

Abstract

Branched hierarchical micro-truss structures may be incorporated into energy-absorbing structures to exhibit a tailored multi-stage buckling response to a range of different compressive loads. Branched hierarchical micro-truss structures may also be configured to function as vascular systems to deliver fluid for thermal load management or altering the aerodynamic properties of a vehicle or structure into which the branched hierarchical micro-truss structure is incorporated. The branched hierarchical micro-truss structure includes a first layer having a series of interconnected struts and a second layer having a series of struts branching outward from an end of each of the struts in the first layer.

Claims

1. A method of manufacturing a branched hierarchical micro-truss structure, the method comprising:

irradiating a first volume of photo-monomer in a reservoir with a first plurality of light beams by directing the first plurality of light beams through a plurality of apertures defined by a first mask to form a first layer of the branched hierarchical micro-truss structure having a plurality of polymer optical waveguides coupled to a substrate;

actuating a moveable platform coupled to the substrate to lift the first layer of the branched hierarchical micro-truss structure out of a remaining volume of photo-monomer; and

irradiating a second volume of photo-monomer with a second plurality of light beams by directing the second plurality of light beams through a plurality of apertures defined by a second mask to form a second layer of the branched hierarchical micro-truss structure having a plurality of polymer optical waveguides, wherein the plurality of polymer optical waveguides of one of the first and second layers branch outward from the plurality of polymer optical waveguides of the other one of the first and second layers, and wherein the plurality of apertures in the second mask is greater in number than that of the plurality of apertures in the first mask.

2. The method of claim 1, further comprising adding or removing a volume of photo-monomer to the reservoir after the irradiating of the first volume of photo-monomer with the first plurality of light beams to form the first layer of the micro-truss structure.

3. The method of claim 1,

wherein the plurality of apertures defined by the second mask differ in at least one of size, shape, and spacing from the apertures defined by the first mask.

4. The method of claim 1, wherein a height of the first volume of photo-monomer is greater than a height of the second volume of photo-monomer.

5. The method of claim 1, further comprising:

actuating the moveable platform to lift the first and second layers of the micro-truss structure out of a remaining volume of the photo-monomer; and

orienting a third plurality of light beams and irradiating a third volume of photo-monomer with the third plurality of light beams to form a third layer of the micro-truss structure having a plurality of polymer optical waveguides branching outward from ends of each of a plurality of the polymer optical waveguides in the second layer.

6. The method of claim 1, further comprising coating at least a portion of the polymer optical waveguides in the first or second layer with a dissimilar material by a process selected from the group of processes consisting of electrodeposition, electroplating, vapor deposition, spray coating, dip coating, and combinations thereof.

7. The method of claim 6, wherein the dissimilar material is coated on a polymer optical waveguide in the first layer axially aligned with a polymer optical waveguide in the second layer.

8. The method of claim 1, further comprising:

depositing a material to completely cover the polymer optical waveguides in the first and second layers; and

selectively removing the polymer optical waveguides to form a plurality of interconnected hollow tubular struts formed out of the material deposited onto the polymer optical waveguides.

9. The method of claim 1, further comprising positioning and orienting the first plurality of light beams such that the polymer optical waveguides in the first layer are arranged in a square-based pyramid configuration or a tetrahedral configuration.

10. A branched hierarchical micro-truss structure, comprising:

a first layer comprising a plurality of interconnected struts; and

a second layer comprising a plurality of struts branching outward from an end of each of a plurality of the struts in the first layer, each strut in the second layer having a first end at the end of one of the struts in the first layer and a second end opposite the first end,

wherein the struts in the first and second layers are hollow tubes,

wherein a first group of struts in the second layer is separated from a second group of struts in the second layer adjacent to the first group of struts, the first group of struts in the second layer branching out from one of the plurality of struts in the first layer and the second group of struts in the second layer branching out from another one of the plurality of struts in the first layer, and

wherein the second ends of the first group of struts in the second layer are not directly connected to the second ends of the second group of struts in the second layer.

11. A vascular system, comprising:

a plurality of layers;

a first layer of the plurality of layers comprising a plurality of hollow tubular struts;

a second layer of the plurality of layers comprising a plurality of hollow tubular struts branching out from an end of each of a plurality of struts in the first layer, wherein the hollow tubular struts in the second layer are in fluid communication with the hollow tubular struts in the first layer;

a fluid contained in the plurality of hollow tubular struts in the first and second layers; and

a flexible membrane coupled to ends of a plurality of hollow tubular struts in an outermost layer of the plurality of layers, wherein the flexible membrane is configured to form dome-shaped protrusions when a positive pressure is applied to the fluid and hemispherical dimples when a negative pressure is applied to the fluid.

12. The vascular system of claim 11, wherein:

the plurality of hollow tubular struts in the first layer are arranged in a square-based pyramid configuration or a tetrahedral configuration; and

the plurality of hollow tubular struts in the second layer are arranged in a square-based pyramid configuration or a tetrahedral configuration.

14. The vascular system of claim 11, further comprising a third layer comprising a plurality of hollow tubular struts branching out from an end of each of a plurality of hollow tubular struts in the second layer, wherein the hollow tubular struts in the third layer are in fluid communication with the hollow tubular struts in the second layer.

15. The vascular system of claim 11, wherein the plurality of hollow tubular struts in each of the first layer and the second layer are polymer optical waveguides.

13. A vascular system, comprising:

a plurality of layers, comprising;

a first layer comprising a plurality of hollow tubular struts; and

a second layer comprising a plurality of hollow tubular struts branching out from an end of each of a plurality of struts in the first layer, each hollow tubular strut in the second layer having a first end at the end of one of the hollow tubular struts in the first layer and a second end opposite the first end,

wherein the hollow tubular struts in the second layer are in fluid communication with the hollow tubular struts in the first layer,

wherein a number of hollow tubular struts in the second layer is greater than a number of hollow tubular struts in the first layer,

wherein a first group of hollow tubular struts in the second layer is separated from a second group of hollow tubular struts in the second layer adjacent to the first group, the first group of hollow tubular struts in the second layer branching out from one of the plurality of hollow tubular struts in the first layer and the second group of hollow tubular struts in the second layer branching out from another one of the plurality of hollow tubular struts in the first layer, and

wherein the second ends of the first group of hollow tubular struts in the second layer are not directly connected to the second ends of the second group of hollow tubular struts in the second layer; and

a faceplate coupled to a plurality of hollow tubular struts in an outermost layer of the plurality of layers, the faceplate defining a plurality of openings aligned with a plurality of openings defined by the plurality of hollow tubular struts in the outermost layer such that a fluid can be delivered through the plurality of openings defined by the faceplate.

16. The vascular system of claim 13, further comprising a third layer of the plurality of layers, the third layer comprising a plurality of hollow tubular struts branching out from the second end of each of a plurality of hollow tubular struts in the second layer, wherein the hollow tubular struts in the third layer are in fluid communication with the hollow tubular struts in the second layer.

17. The vascular system of claim 13, wherein the plurality of hollow tubular struts in each of the first layer and the second layer are polymer optical waveguides.