# US 2019/0315086 A1 · Architected materials for enhanced energy absorption

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- Number: US 2019/0315086 A1
- Document ID: US20190315086A1
- Status: Published application
- Kind: A1
- Application number: 16/425,566
- Filed: 2019-05-29
- Published: 2019-10-17
- Earliest claimed: 2013-03-08
- Assignees: HRL Laboratories, LLC
- Applicants: Hrl Laboratories, LLC
- Inventors: Jacob M. Hundley; Tobias A. Schaedler; Sophia S. Yang; Alan J. Jacobsen
- Web page: https://patentgrep.com/patent/US20190315086A1

## CPC

- B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
- B29C 33/3835: {Designing moulds, e.g. using CAD-CAM}
- B29C 33/3842: {Manufacturing moulds, e.g. shaping the mould surface by machining}
- B29C 33/424: {Moulding surfaces provided with means for marking or patterning (for injection moulding B29C45/372)}
- B29C 64/124: using layers of liquid which are selectively solidified
- B29C 64/129: characterised by the energy source therefor, e.g. by global irradiation combined with a mask
- B29C 64/135: the energy source being concentrated, e.g. scanning lasers or focused light sources
- B32B 3/00: Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 3/14: characterised by a face layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 3/18: characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 3/20: of hollow pieces, e.g. tubes; of pieces with channels or cavities
- 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}
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence)
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 7/00: Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B 7/04: Interconnection of layers
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/00: Layered products comprising a {layer of a} particular substance not covered by groups B32B11/00 - B32B29/00
- B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/04: comprising such {particular} substance 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 glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 15/00: Layered products comprising {a layer of} metal
- B32B 15/04: 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)}
- B32B 27/00: Layered products comprising {a layer of} synthetic resin {(fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18)}
- B32B 27/06: 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 layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/365: {comprising polycarbonates}
- B29C 2035/0827: {using UV radiation}
- B32B 2250/00: Layers arrangement
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2264/00: Composition or properties of particles which form a particulate layer or are present as additives
- B32B 2264/107: Ceramic
- B32B 2307/40: having particular optical properties
- B32B 2307/558: Impact strength, toughness
- B32B 2307/56: Damping, energy absorption
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/728: Hydrophilic
- B32B 2307/73: Hydrophobic
- B32B 2307/732: Dimensional properties
- B32B 2419/00: Buildings or parts thereof
- B32B 2605/00: Vehicles
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- Y10T 29/49826: Assembling or joining
- Y10T 428/24149: Honeycomb-like
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 3)

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.

### Claim 5 (depends on 3)

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.

### Claim 6 (depends on 1)

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.

### Claim 7 (depends on 6)

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

### Claim 8 (depends on 6)

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