Multi-chemistry microlattice structures and methods of manufacturing the same

• US 10,456,956 B1
• Filed: 07/14/2017
• Issued: 10/29/2019
• Est. Priority Date: 12/19/2013
• Status: Active Grant

• Current Assignee: HRL Laboratories LLC (The Boeing Co.)
• Original Assignee: HRL Laboratories LLC (The Boeing Co.)
• Inventors: Yang, Sophia S., Jacobsen, Alan J., Eckel, Zak C., Hundley, Jacob M., Carter, William
• Primary Examiner(s): Sample, David
• Assistant Examiner(s): Gugliotta, Nicole T
• Application Number:
  US15/650,335
• Time in Patent Office: 837 Days
• Field of Search: None
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 35/0894 provided with masks or diaphragms
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/20 Exposure; Apparatus therefor photographic printing apparatus for making copies G03B27/00
• CPC Class Codes: G03F 7/201 characterised by an oblique exposure; characterised by the use of plural sources; characterised by the rotation of the optical device; characterised by a relative movement of the optical device, the light source, the sensitive system or the mask
• CPC Class Codes: G03F 7/2012 using liquid photohardening compositions, e.g. for the production of reliefs such as flexographic plates or stamps
• CPC Class Codes: G03F 7/26 Processing photosensitive materials; Apparatus therefor G03F7/12 - G03F7/24 take precedence

Abstract

A multi-chemistry structure includes: a plurality of interconnected polymer struts arranged in a lattice; a first layer of the lattice including a first array of first unit cells; a second layer of the lattice including a second array of second unit cells; at least one region of the lattice being formed of a first polymer; and at least one region of the lattice being formed of a second polymer different from the first polymer.

Claims

1. A multi-chemistry structure comprising:

a plurality of interconnected polymer struts arranged in an integrated lattice comprising a plurality of unit cells;

a first layer of the lattice being formed of a first photopolymerized polymer; and

a second layer of the lattice being formed of a second photopolymerized polymer different from the first photopolymerized polymer,

wherein;

the first layer is substantially continuous across the lattice and comprises 50% or more of each unit cell;

the second layer comprises a remainder of each unit cell;

the first layer is free of the second photopolymerized polymer,

the second layer is free of the first photopolymerized polymer, and

the first and second layers together define the boundary of a simple polygonal or polyhedral unit cell.

2. A multi-chemistry structure comprising:

a plurality of interconnected polymer struts arranged in an integrated lattice;

a first region of the lattice comprising an array of first unit cells, the first region being formed of a first photopolymerized polymer; and

a second region of the lattice comprising an array of caps interpolated between the first unit cells of the first region, the array of caps forming an array of second unit cells, each of the second unit cells having a smaller area or volume than each of the first unit cells, and the second region being formed of a second photopolymerized polymer different from the first photopolymerized polymer;

wherein the first photopolymerized polymer is chemically bonded to the second photopolymerized polymer at an interface between the first and second regions,

wherein the first region is free of the second photopolymerized polymer, and

wherein the second region is free of the first photopolymerized polymer.

3. A multi-chemistry structure comprising:

a plurality of interconnected polymer struts arranged in a first integrated lattice comprising an array of unit cells comprising two or more rows and two or more columns, the first integrated lattice being formed of a first photopolymerized polymer; and

a second photopolymerized polymer different from the first photopolymerized polymer, the second photopolymerized polymer encapsulating some of the polymer struts at regular intervals such that the polymer struts comprise encapsulated polymer struts that each continuously span at least two contiguous rows of the two or more rows and at least two contiguous columns of the two or more columns of the array of unit cells to form a continuous second integrated lattice.

4. A multi-chemistry structure comprising:

a plurality of interconnected polymer struts arranged in an integrated lattice comprising a plurality of unit cells;

at least one region of the lattice being formed of a first photopolymerized polymer; and

at least one region of the lattice being formed of a second photopolymerized polymer different from the first photopolymerized polymer,

wherein;

the plurality of unit cells are bonded to respective second unit cells at a plurality of respective nodes;

regions surrounding the respective nodes are formed of the first photopolymerized polymer and are free of the second photopolymerized polymer;

non-nodal remainder regions of the unit cells are formed of the second photopolymerized polymer and are free of the first photopolymerized polymer; and

the second photopolymerized polymer is more susceptible to etching than the first photopolymerized polymer.

5. The multi-chemistry structure of claim 4, wherein the lattice is coated with a substantially uniform coating.

6. The multi-chemistry structure of claim 5, wherein the substantially uniform coating comprises a third photopolymerized polymer different from the first and second photopolymerized polymers.

7. The multi-chemistry structure of claim 5, wherein the substantially uniform coating comprises a metallic coating.