Methods for manufacture of multilayered multifunctional truss structures and related structures there from

• US 20060080835A1
• Filed: 02/17/2004
• Published: 04/20/2006
• Est. Priority Date: 02/14/2003
• Status: Abandoned Application

• Current Assignee: University of Virginia Patent Foundation (University of Virginia)
• Original Assignee: University of Virginia Patent Foundation (University of Virginia)
• Inventors: Wadley, Haydn N.G., Kooistra, Gregory W.
• Application Number:
  US10/545,042
• Publication Number:
  US 20060080835A1
• Time in Patent Office: Days
• US Class Current: 29/897.340
• CPC Class Codes: B21D 31/043 Making use of slitting discs or punch cutters
• CPC Class Codes: B21D 47/00 Making rigid structural elements or units, e.g. honeycomb structures
• CPC Class Codes: B29D 24/002 formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled totally filled B29D99/0021
• 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 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• 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 27/06 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 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• 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 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• 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: B32B 9/047 made of fibres or filaments
• CPC Class Codes: E04C 2/3405 spaced apart by profiled spacer sheets
• CPC Class Codes: E04C 2002/3488 spaced apart by frame like structures
• CPC Class Codes: Y10T 29/49632 : Metal reinforcement member for nonmetallic, e.g., concrete, structural element
• CPC Class Codes: Y10T 29/49908 : Joining by deforming
• CPC Class Codes: Y10T 29/49915 : Overedge assembling of seated part
• CPC Class Codes: Y10T 29/49924 : of parallel side-by-side elongated members

Abstract

A method for manufacturing multilayered truss cores, which solves, among other things, key issues of bonding monolayered truss cores to one another. A multilayered truss core may be created from a single planar perform of an appropriate geometric pattern. Once the desired preform is manufactured it is then deformed into a three-dimensional (3D) truss network. This approach bypasses the need to stack and join monolayer truss cores, eliminating the additional tooling, lay-up, and interlayer bonding process steps. These multilayered cores may then be attached to facesheets or the like to form multilayered truss core panels or other multifunctional structures.

Claims

1. A method of making a multilayered truss core, said method comprising:

providing a preform member of appropriate topology including a plurality of intersecting members, wherein nodes are formed at said intersections; and

bending said preform member to form a multilayer truss core, wherein;

predetermined selection of said plurality of said nodes remain at least substantially in or are bent at least substantially into a first plane,

predetermined selection of said plurality of said nodes are bent at least substantially into a second plane distal from said first plane, and

predetermined selection of said plurality of said nodes are bent at least substantially into a third plane distal from said first plane and opposite from said second plane, whereby said first plane is between said second plane and said third plane to form said truss core.

2. The method of claim 1, wherein said bending of said preform member results in predetermined selection of said plurality of said nodes are bent at least substantially into a fourth plane that is:

either distal from second plane and opposite direction from said third plane, whereby said second plane is between said first plane and said fourth plane, or

distal from third plane and opposite direction from said second plane, whereby said third plane is between said first plane and said fourth plane.

3. The method of claim 2, further comprising:

bonding a face member in mechanical communication with said truss core.

4. The method of claim 3, further comprising:

bending said truss core and said face member into a desired shape.

5. The method of claim 4, wherein said desired shape comprises a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

6. The method of claim 3, further comprising:

bonding a second face member in mechanical communication with said truss core distal from said first face member.

7. The method of claim 6, further comprising:

bending said truss core, said face member, and said second face member into a desired shape.

8. The method of claim 7, wherein said desired shape comprises a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

9. The method of claim 2, wherein said truss core comprises a trilayered truss core.

10. The method of claim 2, wherein said truss core comprises a pyramidal truss core.

11. The method of claim 2, wherein shape of said truss core is at least one of curved, planar, substantially planar, or has a plurality of curves.

12. The method of claim 2, further comprising:

bending said truss core into a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

13. The method of claim 1, wherein said truss core is curved.

14. The method of claim 1, wherein said truss core is at least substantially planar.

15. The method of claim 1, wherein said truss core is planar.

16. The method of claim 1, wherein said truss core has a plurality of curves.

17. The method of claim 1, wherein said truss core is a bilayered truss.

18. The method of claim 1, wherein said truss core comprises at least one of a pyramidal truss core, septoid truss core or tetrahedral truss core.

19. The method of claim 1, further comprising:

bending said truss core into a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

20. The method of claim 1, wherein said preform is comprised of a material of at least one of metals, metal alloys, inorganic polymers, organic polymers, ceramics, glasses, semiconductors, electronic materials and photonic materials, and all composite derivatives.

21. The method of claim 1, wherein said preform is comprised of a composite formed of a material of at least one of metals, metal alloys, inorganic polymers, organic polymers, ceramics, glasses, semiconductors, electronic materials and photonic materials.

22. The method of claim 1, wherein the topology of said preform member includes at least one of stamped sheet goods, woven textiles, expanded sheet goods, expanded metal, laser cut sheets, perforated sheets, and hollow tube arrays or any combination thereof.

23. The method of claim 1, where the bending of the preform is performed at a temperature range to accommodate the bending.

24. The method of claim 23, wherein the temperature range is at a ductile temperature or range of ductile temperatures for said preform.

25. The method of claim 1, wherein the bending process is accomplished by at least one of devices selected from the group consisting of punch die type tool operations, pushing technique tools, nodal tension expansion operations, pulling technique tools, forging, and electric discharge forming.

26. The method of claim 1, further comprising:

bonding a face member in mechanical communication with said truss core.

27. The method of claim 26, wherein said first face member comprise at least one of a panel, perforated structure, porous structure, mesh structure, aperture sheet, or array of intersecting members structure, or any combination thereof.

28. The method of claim 26, further comprising disposing a first intermediate member between said truss and said face member.

29. The method of claim 28, wherein said first intermediate member comprises at least one of strips of fabric, sheets of fabric, imbedded sensor arrays, or heating wires.

30. The method of claim 26, further comprising:

bending said truss core and said face member into a desired shape.

31. The method of claim 30, wherein said desired shape comprises a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

32. The method of claim 26, further comprising:

placing an element in the interstitial space of said truss core.

33. The method of claim 32, wherein said interstitial element is at least one of the following prism, rod, block, cylinder, three-dimensional structure, battery, electronic component, or computer component.

34. The method of claim 26, wherein said structure has a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

35. The method of claim 26, further comprising:

bonding a second face member in mechanical communication with said truss core distal from said first face member.

36. The method of claim 35, wherein said second face member comprise at least one of a panel, perforated structure, porous structure, mesh structure, aperture sheet, or array of intersecting members structure, or any combination thereof.

37. The method of claim 36, further comprising disposing a second intermediate member between said truss and said second face member.

38. The method of claim 37, wherein said second intermediate member comprises at least one of strips of fabric, sheets of fabric, imbedded sensor arrays, or heating wires.

39. The method of claim 35, further comprising:

bending said truss core, said face member, and said second face member into a desired shape.

40. The method of claim 39, wherein said desired shape comprises a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

41. The method of claim 1, further comprising:

placing an element in the interstitial space of said truss core.

42. The method of claim 41, wherein said interstitial element is at least one of the following prism, rod, block, cylinder, three-dimensional structure, battery, electronic component, computer component.

43. The method of claim 1, wherein at least a portion of the topology of said intersecting members are in the form of periodic shapes comprising either:

diamond, hexagonal, septoid or octagonal, and wherein;

said periodic shapes have some of said connecting members in the interior of said periodic shapes.

44. The method of anyone of claims 1, 2, 26, or 35, wherein said truss core comprises at least one of:

architecture structure (for example;

pillars, walls, shielding, foundations or floors for tall buildings or pillars, wall shielding floors, for regular buildings and houses), civil engineering field structure (for example;

road facilities such as noise resistant walls and crash barriers, road paving materials, permanent and portable aircraft landing runways, pipes, segment materials for tunnels, segment materials for underwater tunnels, tube structural materials, main beams of bridges, bridge floors, girders, cross beams of bridges;

girder walls, piers, bridge substructures, towers, dikes and dams, guide ways, railroads, ocean structures such as breakwaters and wharf protection for harbor facilities, floating piers/oil excavation or production platforms, airport structures such as runways) and machine structure field (frame structures for carrying system, carrying pallets, frame structure for robots, etc.), the automobile (the body, frame, doors, chassis, roof and floor, side beams;

bumpers, etc.), the ship (main frame of the ship, body, deck, partition wall, wall, etc.), freight car (body, frame, floor, wall, etc.), aircraft (wing, main frame, body, floor, etc.), spacecraft (body, frame, floor, wall, etc.), space station (the main body, floor, wall, etc.), and submarine, ship or water craft (the body, frame, etc.).

45. A multilayered truss core structure comprised of:

at least two integrally formed layers of truss arrays, wherein said layers are free of bonds adapted to otherwise join said first and second layers together.

46. The structure of claim 45, wherein said two layers form a bilayered truss core.

47. The structure of claim 46, wherein said bilayered truss core comprises a pyramidal truss core, septoid truss core or tetrahedral truss core.

48. The structure of claim 45, wherein said truss core has a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

49. The structure of claim 45, further comprising an integrally formed third layer immediately adjacent to either said first or second layer.

50. The structure of claim 49, wherein a said third layer are free of bonds between itself and said immediately adjacent said first or second layers.

51. The structure of claim 49, wherein said first, second, and third layers form a trilayered truss core.

52. The structure of claim 49, wherein said trilayered truss core comprises a pyramidal truss core.

53. The structure of claim 45, further comprising:

a face member in mechanical communication with said truss core.

54. The structure of claim 53, wherein said first face member comprise at least one of a panel, perforated structure, porous structure, mesh structure, aperture sheet, or array of intersecting members structure, or any combination thereof.

55. The structure of claim 53, further comprising:

a first intermediate member between said truss and said face member.

56. The structure of claim 55, wherein said first intermediate member comprises at least one of strips of fabric, sheets of fabric, imbedded sensor arrays, or heating wires.

57. The structure of claim 53, further comprising:

an element in the interstitial space of said truss core.

58. The structure of claim 57, wherein said interstitial element is at least one of the following prism, rod, block, cylinder, three-dimensional structure, battery, electronic component, or computer component.

59. The structure of claim 53, wherein said structure is either curved, planar, substantially planar, or has a plurality of curves.

60. The structure of claim 53, further comprising:

a second face member in mechanical communication with said truss core distal from said first face member.

61. The structure of claim 60, wherein said second face member comprise at least one of a panel, perforated structure, porous structure, mesh structure, aperture sheet, or array of intersecting members structure, or any combination thereof.

62. The structure of claim 61, further comprising:

a second intermediate member between said truss and said second face member.

63. The structure of claim 62, wherein said second intermediate member comprises at least one of strips of fabric, sheets of fabric, imbedded sensor arrays, or heating wires.

64. The structure of claim 45, further comprising:

an element in the interstitial space of said truss core.

65. The structure of claim 64, wherein said interstitial element is at least one of the following prism, rod, block, cylinder, three-dimensional structure, battery, electronic component, or computer component.

66. The structure of claim 64, wherein said truss core has a shape that is at least one of curved, planar, substantially planar, or has a plurality of curves.

67. The structure of anyone of claims 45, 53 or 60, wherein said structure comprises at least one of:

architecture structure (for example;

pillars, walls, shielding, foundations or floors for tall buildings or pillars, wall shielding floors, for regular buildings and houses), civil engineering field structure (for example;

road facilities such as noise resistant walls and crash barriers, road paving materials, permanent and portable aircraft landing runways, pipes, segment materials for tunnels, segment materials for underwater tunnels, tube structural materials, main beams of bridges, bridge floors, girders, cross beams of bridges girder walls, piers, bridge substructures, towers, dikes and dams, guide ways, railroads, ocean structures such as breakwaters and wharf protection for harbor facilities, floating piers/oil excavation or production platforms, airport structures such as runways) and machine structure field (frame structures for carrying system, carrying pallets, frame structure for robots, etc.), the automobile (the body, frame, doors, chassis, roof and floor, side beams, bumpers, etc.), the ship (main frame of the ship, body, deck, partition wall, wall, etc.), freight car (body, frame, floor, wall, etc.), aircraft (wing, main frame, body, floor, etc.), spacecraft (body, frame, floor, wall, etc.), space station (the main body, floor, wall, etc.), and submarine, ship or water craft (the body, frame, etc.).

68. A three dimensional multilayered truss core structure comprised of:

at least two integrally formed layers of truss arrays, wherein said layers are integrally formed with one another without casting.

69. The structure of claim 68, further comprising an integrally formed third layer immediately adjacent to either said first or second layer, wherein said third layer is integrally formed with respective said first or second layer without casting.

70. The structure of claim 68, further comprising an integrally formed third layer immediately adjacent to either said first or second layer.

71. The structure of claim 68, further comprising a third layer in mechanical communication with respective said first or second layer.