Architected materials for enhanced energy absorption

• US 10,427,375 B2
• Filed: 06/14/2017
• Issued: 10/01/2019
• Est. Priority Date: 03/08/2013
• Status: Active Grant

• Current Assignee: HRL Laboratories LLC (The Boeing Co.)
• Original Assignee: HRL Laboratories LLC (The Boeing Co.)
• Inventors: Hundley, Jacob M., Schaedler, Tobias A., Yang, Sophia S., Jacobsen, Alan J.
• Primary Examiner(s): Colgan, Lauren R
• Application Number:
  US15/622,518
• Publication Number:
  US 20170274619A1
• Time in Patent Office: 839 Days
• Field of Search: 428116, 428598
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 33/3835 Designing moulds, e.g. using CAD-CAM
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 33/424 Moulding surfaces provided with means for marking or patterning for injection moulding B29C45/372
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B32B 15/00 Layered products comprising a layer of metal
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 2250/00 Layers arrangement
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2264/00 Composition or properties of particles which form a particulate layer or are present as additives
• CPC Class Codes: B32B 2264/107 Ceramic
• CPC Class Codes: B32B 2307/40 having particular optical properties light or UV resistant B32B2307/71
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 27/00 : Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/28 : comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 3/00 : Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/14 : characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side B32B5/02 takes precedence
• CPC Class Codes: B32B 3/18 : characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side B32B5/02 takes precedence
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• CPC Class Codes: B32B 3/26 : characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 7/00 : Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
• CPC Class Codes: B32B 7/04 : Interconnection of layers
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/00 : Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
• CPC Class Codes: B32B 9/005 : comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/04 : comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like

Abstract

A three-dimensional lattice architecture with a thickness hierarchy includes a first surface and a second surface separated from each other with a distance therebetween defining a thickness of the three-dimensional lattice architecture; a plurality of angled struts extending along a plurality of directions between the first surface and the second surface; a plurality of nodes connecting the plurality of angled struts with one another forming a plurality of unit cells. At least a portion of the plurality of angled struts are internally terminated along the thickness direction of the lattice structure and providing a plurality of internal degrees of freedom towards the first or second surface of the lattice architecture.

Claims

1. A three-dimensional lattice architecture with a thickness hierarchy, comprising:

a first surface and a second surface separated from each other with a distance therebetween defining a thickness and a thickness direction of the lattice architecture; and

a plurality of lattice structures stacked on one another in the thickness direction forming an interface in between,

wherein a set of unit cell parameters of a lattice structure of the plurality of lattice structures is different from a set of unit cell parameters of a neighboring lattice structure,

wherein the plurality of lattice structures comprises a first lattice structure and a second lattice structure bond through a first interface to the first lattice structure, and

wherein a portion of ends of the first lattice structure that are on the first interface and a portion of ends of the second lattice structure that are on the first interface do not contact each other.

2. The three-dimensional lattice architecture of claim 1, further comprising a facesheet located at the interface between two neighboring lattice structures.

3. The three-dimensional lattice architecture of claim 1, wherein the first surface and/or the second surface is free of any facesheets.

4. The three-dimensional lattice architecture of claim 1, further comprising

a first facesheet bonded to one of the first surface and the second surface.

5. The three-dimensional lattice architecture of claim 4, wherein the first facesheet comprises a facesheet material selected from the group consisting of metallic materials, polymeric materials, ceramic materials and composite materials.

6. The three-dimensional lattice architecture of claim 4, further comprising a second facesheet bonded to the remaining one of the first surface and the second surface.

7. The three-dimensional lattice architecture of claim 6, wherein the second facesheet comprises a facesheet material selected from the group consisting of metallic materials, polymeric materials, ceramic materials and composite materials.

8. The three-dimensional lattice architecture of claim 1, wherein each of the lattice structures comprises a lattice structure material selected from the group consisting of solid metallic materials, solid polymeric materials, solid ceramic and solid composite materials.

9. The three-dimensional lattice architecture of claim 1, wherein each of the lattice structures comprises a lattice structure material selected from the group consisting of hollow metallic materials, hollow polymeric materials, hollow ceramic materials and hollow composite materials.

10. A method of manufacturing a three-dimensional lattice architecture with a thickness hierarchy, the method comprising:

providing a first volume of photo-monomer in a first container;

exposing the first volume of photo-monomer to collimated light through a first mask, the collimated light passing through a plurality of first apertures of the first mask at a first non-perpendicular angle with respect to the mask to form a first plurality of angled polymer struts in the photo-monomer at the non-perpendicular angle to form a first three-dimensional lattice structure having a first set of unit cell parameters, a first top surface and a first bottom surface;

providing a second volume of photo-monomer in a second container;

exposing the second volume of photo-monomer to collimated light through a second mask, the collimated light passing through a plurality of second apertures of the second mask at a second non-perpendicular angle with respect to the mask to form a second plurality of angled polymer struts in the photo-monomer at the non-perpendicular angle to form a second three-dimensional lattice structure having a second set of unit cell parameters, a second top surface and a second bottom surface; and

connecting the first top surface with the second bottom surface;

wherein

the first set of unit cell parameters and the second set of unit cell parameters are different, and

wherein a portion of ends of the first plurality of angled polymer struts of the first three-dimensional lattice structure that are on the first top surface and a portion of ends of the second plurality of angled polymer struts of the second lattice structure that are on the second bottom surface do not contact each other.

11. The method of claim 10, wherein the first container and the second container are the same container, and the connection between the first top surface and the second bottom surface is controlled through the exposure intensity.

12. The method of claim 10, wherein the first container and the second container are different containers, and the connecting of the first top surface with the second bottom surface is through adhesive, UV flash-weld, welding under pressure at elevated temperature, thermal post-cure, heat bonding, and/or solvent bonding.

13. The method of claim 10, wherein the second container comprises the first container, and the connecting of the first top surface with the second bottom surface is through controlling the exposure intensity.