Functionally-graded three-dimensional ordered open-cellular microstructure and method of making same

• US 8,195,023 B1
• Filed: 12/18/2008
• Issued: 06/05/2012
• Est. Priority Date: 12/18/2008
• Status: Active Grant

• Current Assignee: HRL Laboratories LLC (The Boeing Co.)
• Original Assignee: HRL Laboratories LLC (The Boeing Co.)
• Inventors: Jacobsen, Alan J., Olson, Gregory L.
• Primary Examiner(s): Rojas, Omar
• Application Number:
  US12/317,210
• Time in Patent Office: 1,265 Days
• Field of Search: 385/146
• US Class Current: 385/146
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: G02B 6/10 of the optical waveguide type G02B6/02, G02B6/24 take precedence; devices or arrangements for the control of light by electric, magnetic, electro-magnetic or acoustic means G02F1/00; transferring the modulation of modulated light G02F2/00; optical logic elements G02F3/00; optical analogue/digital converters G02F7/00
• CPC Class Codes: G02B 6/138 by using polymerisation
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images

Abstract

A method for creating or forming a functionally graded 3D ordered open-cellular microstructure, and a functionally graded 3D ordered open-cellular microstructure. In one embodiment, the functionally-graded three-dimensional ordered open-cellular microstructure includes a first three-dimensional interconnected pattern of polymer waveguides having a first three-dimensional pattern; a second three-dimensional interconnected pattern of polymer waveguides having a second three-dimensional pattern differing from the first three-dimensional pattern; and an interface connected with the first three-dimensional interconnected pattern of polymer waveguides and the second three-dimensional interconnected pattern of polymer waveguides. Here, the term “functionally graded” refers to a spatial variation in the physical microstructure—and thus the properties—through the thickness of the material.

Claims

1. A functionally-graded three-dimensional ordered open-cellular microstructure comprising:

a first three-dimensional interconnected pattern of polymer waveguides having a first three-dimensional pattern;

a second three-dimensional interconnected pattern of polymer waveguides having a second three-dimensional pattern differing from the first three-dimensional pattern; and

an interface connected with the first three-dimensional interconnected pattern of polymer waveguides and the second three-dimensional interconnected pattern of polymer waveguides.

2. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 1, wherein the interface is a third three-dimensional interconnected pattern of polymer waveguides having a third three-dimensional pattern differing from the first three-dimensional pattern and the second three-dimensional pattern.

3. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 1, wherein the first and second three-dimensional patterns have order in three dimensions.

4. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 1, further comprising:

a plurality of first truss elements defined by a plurality of first self-propagating polymer waveguides of the first three-dimensional interconnected pattern of polymer waveguides and extending along a first direction;

a plurality of second truss elements defined by a plurality of second self-propagating polymer waveguides of the first three-dimensional interconnected pattern of polymer waveguides and extending along a second direction;

a plurality of third truss elements defined by a plurality of third self-propagating polymer waveguides of the first three-dimensional interconnected pattern of polymer waveguides and extending along a third direction;

a plurality of fourth truss elements defined by a plurality of fourth self-propagating polymer waveguides of the second three-dimensional interconnected pattern of polymer waveguides and extending along a fourth direction;

a plurality of fifth truss elements defined by a plurality of fifth self-propagating polymer waveguides of the second three-dimensional interconnected pattern of polymer waveguides and extending along a fifth direction; and

a plurality of sixth truss elements defined by a plurality of sixth self-propagating polymer waveguides of the second three-dimensional interconnected pattern of polymer waveguides and extending along a sixth direction;

wherein the first, second, and third truss elements interpenetrate each other at a plurality of first nodes to form a first continuous material, wherein the fourth, fifth, and sixth truss elements interpenetrate each other at a plurality of second nodes to form a second continuous material, and wherein the interface comprises a plurality of third nodes for connecting the first continuous material to the second continuous material.

5. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 1, wherein the interface comprises a plurality of truss elements respectively extending along different directions,

wherein the truss elements interpenetrate each other at a plurality of nodes to form a self-supporting structure.

6. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 5, wherein at least two of the truss elements intersect each other at a node of the plurality of nodes at non-perpendicular angles.

7. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 5, wherein at least three of the truss elements intersect each other at a node of the plurality of nodes at non-perpendicular angles.

8. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 5, wherein at least four of the truss elements intersect each other at a node of the plurality of nodes at non-perpendicular angles.

9. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 1, wherein the second three-dimensional interconnected pattern of polymer waveguides is entirely within the first three-dimensional interconnected pattern of polymer waveguides.

10. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 9, wherein the first three-dimensional interconnected pattern of polymer waveguides and the second three-dimensional interconnected pattern of polymer waveguides are substantially identical in volume.

11. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 1, wherein the second three-dimensional interconnected pattern of polymer waveguides has a first portion formed within the first three-dimensional interconnected pattern of polymer waveguides and a second portion formed outside of the first three-dimensional interconnected pattern of polymer waveguides.

12. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 1, wherein each of the polymer waveguides has an axial diameter of not greater than about 500 μ

m.

13. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 11, wherein each of the polymer waveguides has an axial diameter of not greater than about 200 μ

m.

14. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 2, wherein the first, second, and third three-dimensional patterns have order in three dimensions.

15. A functionally-graded three-dimensional ordered open-cellular microstructure comprising:

a first continuous material comprising;

a plurality of first truss elements defined by a plurality of first self-propagating polymer waveguides of a first three-dimensional interconnected pattern and extending along a first direction;

a plurality of second truss elements defined by a plurality of second self-propagating polymer waveguides of the first three-dimensional interconnected pattern and extending along a second direction;

a plurality of third truss elements defined by a plurality of third self-propagating polymer waveguides of the first three-dimensional interconnected pattern and extending along a third direction, the first, second, and third truss elements interpenetrating each other at a plurality of first nodes to form the first continuous material;

a second continuous material comprising;

a plurality of fourth truss elements defined by a plurality of fourth self-propagating polymer waveguides of a second three-dimensional interconnected pattern and extending along a fourth direction;

a plurality of fifth truss elements defined by a plurality of fifth self-propagating polymer waveguides of the second three-dimensional interconnected pattern and extending along a fifth direction; and

a plurality of sixth truss elements defined by a plurality of sixth self-propagating polymer waveguides of the second three-dimensional interconnected pattern and extending along a sixth direction, the fourth, fifth, and sixth truss elements interpenetrate each other at a plurality of second nodes to form the second continuous material; and

a interface comprising a plurality of third nodes, the third nodes connecting the first continuous material to the second continuous material.

16. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 15, wherein the second continuous material is entirely within the first continuous material.

17. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 16, wherein the first continuous material and the second continuous material are substantially identical in volume.

18. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 15, wherein the second continuous material has a first portion formed within the first continuous material and a second portion formed outside of the continuous material.

19. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 15, wherein each of the truss elements has an axial diameter of not greater than about 500 μ

m.

20. The functionally-graded three-dimensional ordered open-cellular microstructure of claim 19, wherein each of the truss elements has an axial diameter of not greater than about 200 μ

m.