Three-dimensional ordered diamond cellular structures and method of making the same

• US 9,229,162 B1
• Filed: 01/31/2011
• Issued: 01/05/2016
• Est. Priority Date: 10/13/2006
• Status: Active Grant

• Current Assignee: HRL Laboratories LLC (The Boeing Co.)
• Original Assignee: HRL Laboratories LLC (The Boeing Co.)
• Inventors: Roper, Christopher S., Carter, William B., Jacobsen, Alan J., Schaedler, Tobias
• Primary Examiner(s): Vo, Hai
• Application Number:
  US13/017,704
• Time in Patent Office: 1,800 Days
• Field of Search: 428/306.6, 428/309.9
• US Class Current: 1/1
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 41/025 having hollow walls
• CPC Class Codes: B29C 67/20 for porous or cellular articles, e.g. of foam plastics, coarse-pored chemical aspects of working up macro-molecular substances to porous or cellular articles C08J9/00
• CPC Class Codes: B82Y 20/00 Nanooptics, e.g. quantum optics or photonic crystals
• CPC Class Codes: C23C 16/01 on temporary substrates, e.g. substrates subsequently removed by etching
• CPC Class Codes: C23C 16/045 Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
• CPC Class Codes: C23C 16/06 characterised by the deposition of metallic material
• CPC Class Codes: C23C 16/27 Diamond only
• CPC Class Codes: C23C 16/30 Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
• CPC Class Codes: G02B 2006/1219 Polymerisation
• CPC Class Codes: G02B 6/12002 Three-dimensional structures
• CPC Class Codes: G02B 6/1221 made from organic materials
• CPC Class Codes: G02B 6/138 by using polymerisation
• CPC Class Codes: Y10T 428/249978 Voids specified as micro
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition

Abstract

Various implementations and embodiments relate to three-dimensional open cellular diamond micro-truss structures and methods.

Claims

1. A three-dimensional micro-truss structure comprising an interconnected ordered network of interpenetrating diamond tubes, wherein the ordered network comprises a plurality of first diamond tubes defined by a plurality of first self-propagating polymer waveguides extending along a first direction, a plurality of second diamond tubes defined by a plurality of second self-propagating polymer waveguides extending along a second direction, and a plurality of third diamond tubes defined by a plurality of third self-propagating polymer waveguides extending along a third direction, wherein the first, second, and third micro-truss diamond tubes interpenetrate each other at a plurality of nodes to form a continuous material, wherein the interconnected network of interpenetrating diamond tubes comprises an ordered diamond micro-truss network comprising a network of hollow tubes comprising diamond, and wherein the hollow tubes comprise bilayer walls comprising diamond and a material comprising at least one of:

refractory metals, ceramics, silicon carbide, silicon nitride, hafnium carbide, chromium carbide, boron nitride, boron carbide, aluminum oxide, titanium diboride, titanium nitride, zirconium dioxide, titanium carbide, titanium carbonitride, tantalum carbide, tantalum nitride, or combinations thereof.

2. The three-dimensional micro-truss structure of claim 1, wherein the interconnected ordered network of interpenetrating diamond tubes are formed from a template comprising a plurality of microtruss struts interpenetrating each other at a plurality of nodes to form a continuous material.

3. The three-dimensional micro-truss structure of claim 2, wherein the interconnected ordered network of interpenetrating diamond tubes comprise an image of a polymer template comprised of an interconnected pattern of self-propagating waveguides.

4. The three-dimensional micro-truss structure of claim 1, wherein the interconnected ordered network of interpenetrating diamond tubes comprise an image of a polymer template comprised of an interconnected pattern of self-propagating waveguides.

5. The three-dimensional micro-truss structure of claim 1, wherein the material comprises ceramic.

6. The three-dimensional micro-truss structure of claim 1, wherein the material comprises silicon nitride.

7. The three-dimensional micro-truss structure of claim 1, wherein the material comprises titanium nitride.

8. The three-dimensional micro-truss structure of claim 1, wherein the material comprises titanium carbide.

9. The three-dimensional micro-truss structure of claim 1, wherein the material comprises a refractory metal.

10. A three-dimensional micro-truss structure comprising an interconnected ordered network of interpenetrating diamond tubes, wherein the ordered network comprises a plurality of first diamond tubes defined by a plurality of first self-propagating polymer waveguides extending along a first direction, a plurality of second diamond tubes defined by a plurality of second self-propagating polymer waveguides extending along a second direction, and a plurality of third diamond tubes defined by a plurality of third self-propagating polymer waveguides extending along a third direction, wherein the first, second, and third micro-truss diamond tubes interpenetrate each other at a plurality of nodes to form a continuous material, wherein the interconnected network of interpenetrating diamond tubes comprises an ordered diamond micro-truss network comprising a network of hollow tubes comprising diamond, and wherein the hollow tubes comprise bilayer walls comprising diamond, and wherein the bilayer walls comprise Ni, Cr, Cu, or alloys thereof.

11. A diamond sandwich panel, the panel comprising:

a) two face sheets; and

b) a core comprising an ordered three-dimensional open-cellular diamond micro-truss structure disposed between the two face sheets, wherein the ordered three-dimensional open-cellular diamond micro-truss structure comprises interconnected network of interpenetrating micro-truss, wherein the ordered network comprises a plurality of first diamond tubes defined by a plurality of first self-propagating diamond waveguides extending along a first direction, a plurality of second diamond tubes defined by a plurality of second self-propagating diamond waveguides extending along a second direction, and a plurality of third diamond tubes defined by a plurality of third self-propagating diamond waveguides extending along a third direction, wherein the first, second, and third micro-truss diamond tubes interpenetrate each other at a plurality of nodes to form a continuous material, wherein the three-dimensional ordered cellular diamond micro-truss structure comprises a network of hollow tubes comprising diamond, and wherein the hollow tubes comprise bilayer walls of diamond and a material comprising at least one of;

refractory metals, ceramics, silicon carbide, silicon nitride, hafnium carbide, chromium carbide, boron nitride, boron carbide, aluminum oxide, titanium diboride, titanium nitride, zirconium dioxide, titanium carbide, titanium carbonitride, tantalum carbide, tantalum nitride, or combinations thereof.

12. The diamond sandwich panel structure of claim 11, wherein the face sheets comprise diamond.

13. The diamond sandwich panel structure of claim 11, wherein the three-dimensional ordered cellular diamond micro-truss structure comprises an interconnected pattern of polymer self-propagating waveguides.