Three-dimensional ordered open-cellular structures

• US 8,197,930 B1
• Filed: 05/10/2007
• Issued: 06/12/2012
• Est. Priority Date: 05/10/2007
• Status: Active Grant

• Current Assignee: HRL Laboratories LLC (The Boeing Co.)
• Original Assignee: HRL Laboratories LLC (The Boeing Co.)
• Inventors: Jacobsen, Alan J., Barvosa-Carter, William B.
• Primary Examiner(s): Vo, Hai
• Application Number:
  US11/801,908
• Time in Patent Office: 1,860 Days
• Field of Search: 428/315.5, 428/315.7, 385/129, 385/130, 385/131, 430/290, 430/396
• US Class Current: 428/315.5
• 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: G02B 6/0065 Manufacturing aspects; Material aspects
• CPC Class Codes: G02B 6/138 by using polymerisation
• CPC Class Codes: Y10T 428/249978 Voids specified as micro
• CPC Class Codes: Y10T 428/249979 Specified thickness of void-containing component [absolute or relative] or numerical cell dimension

Abstract

A three-dimensional ordered open-cellular structure. In one embodiment, the structure includes: a plurality of first truss elements defined by a plurality of first self-propagating polymer waveguides and extending along a first direction; a plurality of second truss elements defined by a plurality of second self-propagating polymer waveguides and extending along a second direction; and a plurality of third truss elements defined by a plurality of third self-propagating polymer waveguides and extending along a third direction. The first, second, and third truss elements interpenetrate each other at a plurality of nodes to form a continuous material, and the three-dimensional structure is self-supporting.

Claims

1. A three-dimensional ordered open-cellular structure comprising:

a plurality of nodes disposed in at least two parallel planes, each of the nodes being located at an intersection of at least three self-propagating polymer waveguides of at least;

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

a plurality of second truss elements defined by a second plurality of self-propagating polymer waveguides and extending along a second direction; and

a plurality of third truss elements defined by a third plurality of self-propagating polymer waveguides and extending along a third direction,

wherein all waveguides of each of the first plurality, second plurality, and third plurality of self-propagating polymer waveguides are parallel to each other and substantially straight,

wherein the first plurality of self-propagating polymer waveguides intersect with the second plurality of self-propagating polymer waveguides at the nodes to define the parallel planes, and

wherein the third plurality of self-propagating polymer waveguides intersect with the parallel planes at non-perpendicular angles.

2. The three-dimensional ordered open-cellular structure of claim 1, wherein the first plurality, second plurality, and third plurality of self-propagating polymer waveguides interpenetrate each other at the nodes to form a continuous material.

3. The three-dimensional ordered open-cellular structure of claim 2, wherein the continuous material substantially lacks interior boundaries.

4. The three-dimensional ordered open-cellular structure of claim 2, wherein each of the nodes is formed of the continuous material.

5. The three-dimensional ordered open-cellular structure of claim 1, wherein the first plurality, second plurality, and third plurality of self-propagating polymer waveguides are configured to axially transfer a mechanical load applied to the three-dimensional ordered open-cellular structure.

6. The three-dimensional ordered open-cellular structure of claim 1, wherein the first plurality, second plurality, and third plurality of self-propagating polymer waveguides are configured to provide the three-dimensional ordered open-cellular structure with a stretch-dominated behavior under a compression load applied to the three-dimensional ordered open-cellular structure.

7. The three-dimensional ordered open-cellular structure of claim 1, wherein the first plurality, second plurality, and third plurality of self-propagating polymer waveguides are configured to provide the three-dimensional ordered open-cellular structure with a compressive elastic modulus directly proportional to both a density of the three-dimensional ordered open-cellular structure and a modulus of a solid material portion of the three-dimensional ordered open-cellular structure.

8. The three-dimensional ordered open-cellular structure of claim 1, wherein the first plurality, second plurality, and third plurality of self-propagating polymer waveguides are configured to provide the three-dimensional ordered open-cellular structure with a compressive elastic modulus (E) determined by:

E=E_s(sin⁴ θ

)(ρ

/ρ

_s)

wherein ρ

is a density of the three-dimensional ordered open-cellular structure, ρ

_s is a density of a solid material portion of the three-dimensional ordered open-cellular structure, θ

is an angle of at least one of the first, second and third truss elements relative to a compression surface of the three-dimensional ordered open-cellular structure, and E_s is a modulus of the solid material portion of the three-dimensional ordered open-cellular structure.

9. The three-dimensional ordered open-cellular structure of claim 1, wherein each of the first plurality, second plurality, and third plurality of self-propagating polymer waveguides has an axial diameter of not greater than about 500 μ

m.

10. The three-dimensional ordered open-cellular structure of claim 1, wherein each of the first plurality, second plurality, and third plurality of self-propagating polymer waveguides has an axial diameter of not greater than about 10 μ

m.

11. The three-dimensional ordered open-cellular structure of claim 1, wherein the three-dimensional ordered open-cellular structure defines a free space of not less than about 40% by volume and not greater than about 99% by volume.

12. The three-dimensional ordered open-cellular structure of claim 1, wherein the three-dimensional ordered open-cellular structure defines a free space of not less than about 70% by volume and not greater than about 95% by volume.

13. The three-dimensional ordered open-cellular structure of claim 1, wherein each of the first plurality, second plurality, and third plurality of self-propagating polymer waveguides has a molecular alignment extending along an axial direction thereof to produce an anisotropic material for providing substantial stiffness and/or strength along the axial direction.

14. The three-dimensional ordered open-cellular structure of claim 1,

wherein each of the first plurality, second plurality, and third plurality of self-propagating polymer waveguides defines an angle relative to a compression surface of the three-dimensional ordered open-cellular structure, and

wherein the respective angles defined by the first plurality, second plurality, and third plurality of self-propagating polymer waveguides substantially equal to one another.

15. The three-dimensional ordered open-cellular structure of claim 1, wherein each of the first plurality, second plurality, and third plurality of self-propagating polymer waveguides comprises a photo-polymer material.

16. The three-dimensional ordered open-cellular structure of claim 1, comprising a plurality of fourth truss elements defined by a fourth plurality of self-propagating polymer waveguides and extending along a fourth direction, all of the fourth plurality of self-propagating polymer waveguides being parallel to each other and substantially straight, wherein the fourth plurality of self-propagating polymer waveguides intersect with the first plurality, second plurality, and third plurality of self-propagating polymer waveguides at the nodes to form a continuous material.

17. The three-dimensional ordered open-cellular structure of claim 16, further comprising a plurality of fifth truss elements defined by a fifth plurality of self-propagating polymer waveguides and extending along a fifth direction, all of the fifth plurality of self-propagating polymer waveguides being parallel to each other and substantially straight, wherein the fifth plurality of self-propagating polymer waveguides intersect with the first plurality, second plurality, third plurality, and fourth plurality of self-propagating polymer waveguides at the nodes to form a continuous material.

18. The three-dimensional ordered open-cellular structure of claim 17, comprising a plurality of sixth truss elements defined by a sixth plurality of self-propagating polymer waveguides and extending along a sixth direction, all of the sixth plurality of self-propagating polymer waveguides being parallel to each other and substantially straight, wherein the sixth plurality of self-propagating polymer waveguides intersect with the first plurality, second plurality, third plurality, fourth plurality, and fifth plurality of self-propagating polymer waveguides at the nodes to form a continuous material.

19. The three-dimensional ordered open-cellular structure of claim 18, further comprising a plurality of seventh truss elements defined by a seventh plurality of self-propagating polymer waveguides and extending along a seventh direction, all of the seventh plurality of self-propagating polymer waveguides being parallel to each other and substantially straight, wherein the seventh plurality of self-propagating polymer waveguides intersect with the first plurality, second plurality, third plurality, fourth plurality, fifth plurality, and sixth plurality of self-propagating polymer waveguides at the nodes to form a continuous material.

20. The three-dimensional ordered open-cellular structure of claim 18, further comprising a plurality of eighth truss elements defined by an eighth plurality of self-propagating polymer waveguides and extending along an eighth direction, all of the eighth plurality of self propagating polymer waveguides being parallel to each other and substantially straight, wherein the eighth plurality of self-propagating polymer waveguides intersect with the first plurality, second plurality, third plurality, fourth plurality, fifth plurality, sixth plurality, and seventh plurality of self-propagating polymer waveguides at the nodes to form a continuous material.

21. A three-dimensional ordered open-cellular structure comprising:

a plurality of nodes disposed in at least two parallel planes, each of the nodes being located at an intersection of at least three polymer optical waveguide truss elements of at least;

a plurality of first polymer optical waveguide truss elements defined by a first plurality of self-propagating polymer waveguides and extending along a first direction;

a plurality of second polymer optical waveguide truss elements defined by a second plurality of self-propagating polymer waveguides and extending along a second direction; and

a plurality of third polymer optical waveguide truss elements defined by a third plurality of self-propagating polymer waveguides and extending along a third direction,

wherein all polymer optical waveguide truss elements of each of the first plurality, second plurality, and third plurality of self-propagating polymer waveguides are parallel to each other and substantially straight,

wherein the first plurality of polymer optical waveguide truss elements intersect with the second plurality of polymer optical waveguide truss elements at the nodes to define the parallel planes, and

wherein the third plurality of polymer optical waveguide truss elements intersect with the parallel planes at non-perpendicular angles.

22. The three-dimensional ordered open-cellular structure of claim 21, wherein the first plurality, second plurality, and third plurality of polymer optical waveguide truss elements interpenetrate each other at the nodes to form a continuous material.

23. The three-dimensional ordered open-cellular structure of claim 22, wherein the continuous material substantially lacks interior boundaries.

24. The three-dimensional ordered open-cellular structure of claim 22, wherein the first plurality, second plurality, and third plurality of polymer optical waveguide truss elements are configured to axially transfer a mechanical load applied to the three-dimensional ordered open-cellular structure.