Architected materials for enhanced energy absorption

Patent metadata

Field	Value
Publication number	US-10994491-B2
Application number	US-201916425566-A
Country	US
Kind code	B2
Filing date	May 29, 2019
Priority date	Mar 8, 2013
Publication date	May 4, 2021
Grant date	May 4, 2021

Abstract

A three-dimensional lattice architecture with a thickness hierarchy includes a first surface and a second surface separated from each other with a distance therebetween defining a thickness of the three-dimensional lattice architecture; a plurality of angled struts extending along a plurality of directions between the first surface and the second surface; a plurality of nodes connecting the plurality of angled struts with one another forming a plurality of unit cells. At least a portion of the plurality of angled struts are internally terminated along the thickness direction of the lattice structure and providing a plurality of internal degrees of freedom towards the first or second surface of the lattice architecture.

First claim

What is claimed is:

1. A method of manufacturing a three-dimensional lattice structure with a thickness hierarchy, the method comprising:
exposing a volume of photo-monomer to collimated light through a mask, the collimated light passing through a plurality of first apertures of the mask at a non-perpendicular angle with respect to the mask to form a plurality of angled polymer struts in the photo-monomer at the non-perpendicular angle to form the three-dimensional lattice structure having a top surface and a bottom surface; and
removing a portion of the three-dimensional lattice structure from one of the top surface and the bottom surface to create the thickness hierarchy.

2. The method of claim 1 , wherein the removing of the portion of the lattice structure is performed through subtractive machining, chemical etching, laser etching, or combinations thereof.

3. The method of claim 1 , further comprising bonding a facesheet to the top surface and/or the bottom surface.

4. The method of claim 3 , wherein the facesheet comprises a material selected from the group consisting of metallic materials, polymeric materials, ceramic materials and composite materials.

5. The method of claim 3 , wherein the bonding of the facesheet is performed utilizing adhesives, thermal bonding, solvent bonding, diffusion bonding, welding, brazing, or UV flash welding.

6. The method of claim 1 , further comprising:
depositing a second material over the three-dimensional lattice structure to form a composite lattice structure; wherein the second material is different from the polymer in the angled polymer struts.

7. The method of claim 6 , further comprising:
removing the polymer from the composite lattice structure.

8. The method of claim 6 , wherein the second material is selected from the group consisting of metallic, polymeric, ceramic and composite materials.

Assignees

• Hrl Lab Llc

Inventors

• Hundley Jacob M
• Schaedler Tobias A
• Yang Sophia S
• Jacobsen Alan J

Classifications

• B29C33/424 Primary

  Moulding surfaces provided with means for marking or patterning (for injection moulding B29C45/372) · CPC title

• B32B3/14

  characterised by a face layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)} · CPC title

• B32B2307/728

  Hydrophilic · CPC title

• B32B3/26

  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 title

• B32B3/02

  characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)} · CPC title