Metal and/or ceramic microlattice structure and its manufacturing method

Patent metadata

Field	Value
Publication number	US-10710337-B2
Application number	US-201916268841-A
Country	US
Kind code	B2
Filing date	Feb 6, 2019
Priority date	Feb 9, 2018
Publication date	Jul 14, 2020
Grant date	Jul 14, 2020

Abstract

A metal and/or ceramic microlattice structure, comprising an alternation of first layers and of second layers formed by tubes, and interlocking with each other in order to form open loops cooperating two by two in order to form nodes of an articulated/ball-joint nature.

First claim

The invention claimed is:

1. Metal and/or ceramic microlattice structure ( 1 ), comprising an alternation of first layers (C 1 ) and of second layers (C 2 ) in a first direction (D 1 ) of the structure;
each first layer (C 1 ) comprising a plurality of first tubes ( 2 . 1 ) each extending in a plane parallel to a first reference plane (P 1 ) defined by said first direction (D 1 ) of the structure as well as by a second direction (D 2 ) orthogonal to the first;
each second layer (C 2 ) comprising a plurality of second tubes ( 2 . 2 ) each extending in a plane parallel to a second reference plane (P 2 ) defined by said first direction (D 1 ) of the structure as well as by a third direction (D 3 ) orthogonal to the first and distinct from the second;
each first tube ( 2 . 1 ) defining, in said second direction (D 2 ), an alternation of first and second loops ( 4 a , 4 b ) open, respectively, in a first heading (S 1 ) of the first direction, and in a second heading (S 2 ) of the first direction opposite to the first;
each second tube ( 2 . 2 ) defining, in said third direction (D 3 ), an alternation of third and fourth loops ( 4 c , 4 d ) open, respectively, in the first heading (S 1 ) of the first direction, and in the second heading (S 2 ) of the first direction;
the first and second layers being interlocking with each other in such a way that through each first open loop ( 4 a) of each first tube ( 2 . 1 ) of any given first layer (C 1 ), one of the fourth open loops ( 4 d ) of one of the second tubes ( 2 . 2 ) of the second layer (C 2 ) directly consecutive to said first given layer in the second heading (S 2 ) of the first direction passes, the two loops in question ( 4 a , 4 d ) being rigidly connected to each other at their respective loop bottoms in such a way as to form a first microlattice node ( 8 . 1 );
and in such a way that through each second open loop ( 4 b ) of each first tube ( 2 . 1 ) of said first given layer (C 1 ), one of the third open loops ( 4 c ) of one of the second tubes ( 2 . 2 ) of the second layer (C 2 ) directly consecutive to said first given layer in the first heading (S 1 ) of the first direction passes, the two loops in question ( 4 b , 4 c ) being rigidly connected to each other at their respective loop bottoms in such a way as to form a second microlattice node ( 8 . 2 ).

2. Structure according to claim 1 , characterised in that the first, second, third and fourth open loops ( 4 a - 4 d ) are each in the shape of an arc of a circle, over an angular sector (A 1 ) of between 10 and 180°, and according to a radius of curvature (R) of 0.1 to 10 mm.

3. Structure according to claim 2 , wherein the arc of the circle is between 10 and 180°, and the radius of curvature is between 1 and 2 mm.

4. Structure according to claim 1 , characterised in that in each tube ( 2 . 1 , 2 . 2 ), the open loops ( 4 a - 4 d ) are connected to each other by linking struts ( 6 ) having a length (L) between 20 and 100,000 μm.

5. Structure according to claim 4 , wherein the linking struts have a length between 6 and 12 mm.

6. Structure according to claim 1 , characterised in that said second and third directions (D 2 , D 3 ) are inclined with respect to one another according to an angle of inclination (Ai) ranging from 10 to 90°.

7. Structure according to claim 6 , wherein the angle of inclination is approximately 90°.

8. Structure according to claim 1 , characterised in that-each tube ( 2 . 1 , 2 . 2 ) defines a hollow having a diameter (D) between 10 and 1000 μm.

9. Structure according to claim 1 , characterised in that each tube ( 2 . 1 , 2 . 2 ) has a wall thickness (E) between 0.01 and 300 μm.

10. Structure according to claim 1 , characterised in that each tube ( 2 . 1 , 2 . 2 ) has a periodic shape, the elementary pattern (Me 1 , Me 2 ) of which has a length (L 1 , L 2 ) between 100 and 10,000 μm.

11. Structure according to claim 10 , wherein the elementary pattern has a length between 2 and 4 mm.

12. Structure according to claim 1 , characterised in that two directly consecutive first layers (C 1 ) or two directly consecutive second layers (C 2 ) are spaced apart from each other in the first direction (D 1 ), by a space (Pa 1 , Pa 2 ) of between 100 and 10,000 μm.

13. Structure according to claim 12 , wherein the two directly consecutive first layers or two directly consecutive second layers are spaced apart from each other in the first direction by a space of between 3 and 5 mm.

14. Structure according to claim 1 , characterised in that it has a relative density of approximately 0.005 to 0.015.

15. Structure according to claim 14 , wherein the relative density is approximately 0.01.

16. Structure according to claim 1 , characterised in that it is made from a metal material, from a ceramic material, or according to a combination of the two.

17. Method for manufacturing a metal and/or ceramic microlattice structure ( 1 ) according to claim 16 , characterised in that it comprises the following steps:
creation of a textile support having a shape similar to that of the structure to be made;
deposition of the metal and/or ceramic material onto said textile support.

18. Structure according to claim 16 , wherein the material(s) is(are) selected from nickel, zinc, chromium, tin, copper, gold, silver, platinum, rhodium, aluminium, diamond, DLC, alumina, zirconia, tin oxide, zinc oxide, silicon carbide, silicon nitride, titanium nitride, tantalum nitride, tungsten nitride.

Assignees

• Commissariat Energie Atomique

Inventors

• Dellea Olivier
• Lebaigue Olivier
• Tardif François

Classifications

• Y10T428/249953

  Composite having voids in a component [e.g., porous, cellular, etc.] · CPC title

• G03F7/0037

  Production of three-dimensional images · CPC title

• B81C2201/0108

  Sacrificial polymer, ashing of organics · CPC title

• B32B15/04 Primary

  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 title

• B29C64/10

  Processes of additive manufacturing · CPC title