Multi-chemistry microlattice structures and methods of manufacturing the same

• US 9,738,013 B1
• Filed: 08/18/2014
• Issued: 08/22/2017
• 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:
  US14/462,521
• Time in Patent Office: 1,100 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;

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

a second layer of the lattice comprising a second array of second unit cells on the first layer, the second layer 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 layers,

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

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

2. The multi-chemistry structure of claim 1, wherein the first unit cells of the first layer have different unit sizes than the second unit cells of the second layer.

3. The multi-chemistry structure of claim 2, wherein the first unit cells of the first layer are smaller than the second unit cells of the second layer.

9. The multi-chemistry structure of claim 1, wherein at least one region of the lattice is formed of a third photopolymerized polymer different from the first and second photopolymerized polymers.

10. A method of manufacturing the multi-chemistry structure of claim 1, the method comprising:

irradiating a first photo-monomer with a plurality of collimated light beams to form a first polymer structure; and

irradiating a second photo-monomer different than the first photo-monomer with a plurality of collimated light beams to form a second polymer structure bonded to the first polymer structure.

11. The method of claim 10, wherein:

the irradiating of the first photo-monomer occurs through a first photomask; and

the irradiating of the second photo-monomer occurs through a second photomask different from the first photomask.

12. The method of claim 10, further comprising etching the first and second polymer structure.

13. The method of claim 12, wherein the second polymer structure is more susceptible to etching than the first polymer structure.

14. The method of claim 13, further comprising coating the first and second polymer structures in a uniform coating.

15. The method of claim 14, further comprising removing the first and second polymer structures such that a hollow structure outlined by the uniform coating remains.

16. The method of claim 10, further comprising:

lifting the first polymer structure out of a reservoir containing an unpolymerized volume of the first photo-monomer;

removing the unpolymerized volume of the first photo-monomer from the reservoir;

filling the reservoir with the second photo-monomer; and

lowering the first polymer structure into the reservoir to contact the second photo-monomer before the irradiating of the second photo-monomer with the collimated light beams.

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 at a plurality of nodes;

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

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

6. The multi-chemistry structure of claim 4, wherein the second photopolymerized polymer is more susceptible to etching than the first photopolymerized polymer.

5. A multi-chemistry structure comprising:

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

a first layer of the lattice comprising a first array of first unit cells;

a second layer of the lattice comprising 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,

wherein;

the first polymer is chemically bonded to the second polymer;

the first unit cells are formed of the first and second polymers alternately along the first layer;

the second unit cells are formed of the first and second polymers alternately along the second layer; and

corresponding ones of the second unit cells are formed of different polymers than respective ones of the first unit cells that are bonded to the corresponding ones of the second unit cells.

7. A multi-chemistry structure comprising:

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

a first layer of the lattice comprising a first array of first unit cells;

a second layer of the lattice comprising 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,

wherein;

the first polymer is chemically bonded to the second polymer;

the first and second polymers are immiscible; and

the second polymer is mixed in the first polymer.

8. The multi-chemistry structure of claim 7, wherein:

the lattice is formed of the first polymer; and

microspheres formed of the second polymer are embedded in the lattice.

17. A method of manufacturing the multi-chemistry structure of claim 7, the method comprising:

filling a reservoir with a first photo-monomer adapted to polymerize when exposed to light having a first wavelength;

mixing a second photo-monomer adapted to polymerize when exposed to light having a second wavelength with the first photo-monomer, the first and second photo-monomers being immiscible and different from each other;

irradiating the first photo-monomer with a plurality of collimated light beams having the first wavelength to form a first polymer structure, the first polymer structure comprising the mixed second photo-monomer; and

irradiating the second photo-monomer with light having the second wavelength such that the first polymer structure comprises a mixed second polymer structure.

18. The method of claim 17, wherein the first polymer structure is a microlattice structure.

19. The method of claim 18, wherein the second polymer structure is a plurality of microspheres embedded within the first polymer structure.

20. The method of claim 18, wherein the second polymer structure is an interpenetrating network within the first polymer structure.