WO2009105651A2 - Procédé de fabrication d’une structure cellulaire et structure cellulaire résultante - Google Patents

Procédé de fabrication d’une structure cellulaire et structure cellulaire résultante Download PDF

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Publication number
WO2009105651A2
WO2009105651A2 PCT/US2009/034690 US2009034690W WO2009105651A2 WO 2009105651 A2 WO2009105651 A2 WO 2009105651A2 US 2009034690 W US2009034690 W US 2009034690W WO 2009105651 A2 WO2009105651 A2 WO 2009105651A2
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WO
WIPO (PCT)
Prior art keywords
array
lattice
structural elements
hollow
core
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PCT/US2009/034690
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English (en)
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WO2009105651A3 (fr
Inventor
Haydn N. G. Wadley
Ryan L. Holloman
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University Of Virginia Patent Foundation
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Publication date
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Publication of WO2009105651A2 publication Critical patent/WO2009105651A2/fr
Publication of WO2009105651A3 publication Critical patent/WO2009105651A3/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3477—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by tubular elements parallel to the sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2002/3488—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by frame like structures

Definitions

  • Sandwich panel structures with light cellular cores shall be used for the efficient support of stresses which subject the panel to bending or buckling deformations. Similar panels with high strength and/or large densif ⁇ cation strains shall also be also used for impact and blast mitigation. Panels in which the cell spaces within the core are made from ballistic resistant materials also offer promise for impeding the penetration of projectiles. They could be used to contain the fragments created by disintegration of an engine, or those created by an explosion.
  • An aspect of an embodiments of the present invention comprises, but not limited thereto, the following: cellular structures that provide metallic, ceramic and polymeric materials in easily adjusted topologies ranging from prismatic to prismatic plus honeycomb to purely honeycomb with relative densities from less than about 0.01 to more than about 90%.
  • An aspect of various embodiments of the present invention comprises, but not limited thereto, the following: structures in which the internal cell volumes are filled, fully or partially with other materials including cellular structures. Several simple methods for the fabrication of such structures are also proposed and demonstrated.
  • the empty lattice and foam filled configurations provide a rigid structure well suited for the impact or blast mitigation. Also, by inserting anti-ballistic materials into the hollow rods, these structures can be tailored to resist ballistic impacts.
  • An aspect of an embodiments of the present invention may provide a number of novel and nonobvious features, elements and characteristics, such as but not limited thereto, the following: the use of simple, low cost material forms to design and construct optimized sandwich panels with cores that defeat specific combinations of dynamic and static loadings.
  • the lightweight periodic cellular structure has a stacked array of hollow or solid structural elements that are bonded at their contact points in order to form a stacked lattice structure. Further arrays may be stacked onto the stacked lattice structure in order to form a periodic cellular structure of varying thickness and depth. Also, structural panels may be added to parallel exterior edges of the stacked lattice structure to form a structural panel.
  • the hollow structural elements are provided with wicking elements along their interior walls to facilitate heat transfer through the periodic cellular structure. Liquid may also be introduced into the hollow structural elements to further facilitate heat transfer through the periodic cellular structure.
  • the cellular structure may be utilized as light weight current collectors, such as electrodes, anodes, and cathodes.
  • the method of manufacturing the periodic cellular structure can accommodate a variety of cross-sectional shapes for the hollow structural members. In addition, the method may introduce a variety of stacking offset angles to vary the lattice shape and resultant mechanical characteristics of the periodic cellular structure. Finally, the method also allows for the bending of the array of hollow or solid structural elements into an array of hollow pyramidal truss elements that can be used to form a stacked pyramidal structure to serve as an alternative core of the periodic cellular structure.
  • the present invention lightweight periodic cellular structure provides a first array of hollow and/or solid structural elements located in a first plane along a first axis; and a second array of hollow and/or solid structural elements located in a second plane along a second axis, wherein the second array is stacked immediately on top of the first array and wherein the first axis and the second axis are offset at a desired offset angle, and wherein the second array is bonded to the first array at points of contact where the first array and the second array meet to form a stacked lattice structure.
  • the present invention provides a method of constructing a lightweight periodic cellular structure comprising the steps of: arranging a first array of parallel hollow and/or solid structural elements in a first plane along a first axis; stacking a second array of parallel hollow and/or solid structural elements in a second plane along a second axis, wherein the first axis and the second axis are offset at a desired offset angle and the second plane is parallel and disposed on the first plane at a plurality of contact points; and bonding the second array to the first array at the plurality of contact points to form a stacked lattice structure.
  • the present invention arranging a first array of hollow and/or solid parallel structural elements in a first plane along a first axis; stacking a second array of hollow and/or parallel structural elements in a second plane along a second axis, wherein said first axis and said second axis are offset at a desired offset angle and said second plane is parallel and disposed on the first plane at a plurality of contact points; bonding the second array to said first array at said plurality of contact points to form a stacked lattice structure; and bending said stacked lattice structure to a desired bending angle at a select number of said contact points to form a pyramidal cellular core.
  • An aspect of an embodiment (or partial embodiment) comprises a cellular lattice structure.
  • the cellular lattice structure may comprise: a first array of structural elements located in a first plane along a first axis; a second array of structural elements disposed on a second plane along a second axis, wherein the second array is disposed on top of the first array and wherein the first axis and the second axis are offset at a desired offset angle, and wherein the second array is bonded to the first array at points of contact wherein the first array and the second array meet; and a third array of structural elements located essentially vertically crosswise to the first array and the second array.
  • the lattice may further comprise inserts disposed in the structural elements of the first array, the second array, or the third array or any combination thereof. It should be appreciated that not every contact point is bonded or bonded the same.
  • An aspect of an embodiment comprises a method of making a cellular lattice structure.
  • the method may comprise: providing a first array of structural elements located in a first plane along a first axis; placing a second array of structural elements located in a second plane along a second axis, wherein the second array is disposed on the first array and wherein the first axis and the second axis are offset at a desired offset angle, and wherein the second array is bonded to the first array at points of contact where the first array and the second array meet; and disposing a third array of structural elements located essentially vertically crosswise to the first array and the second array.
  • the method may further comprise: disposing inserts in the structural elements of the first array, the second array, or third array, or any combination thereof.
  • FIG. 1 is a photographic depiction of a perspective view of a stacked lattice core structure of the present invention where the hollow tube arrays are stacked in alternating perpendicular arrays and bonded to form a stacked lattice core.
  • FIG. 2 is an photographic depiction of a plan view of a two-layer stacked lattice structure of the present invention where the two hollow tube or solid ligament arrays are stacked and bonded such that the second wire array is offset at an angle less than 90 degrees from the first hollow tube or solid ligament array.
  • FIG. 3 is a schematic illustration of a perspective view of the stacked lattice periodic cellular structure of the present invention where the hollow tube or solid ligament arrays are stacked in alternating perpendicular arrays and bonded to form a stacked lattice core and structural panels have been bonded to the orthogonal edges of the periodic cellular core to form a structural panel.
  • FIG. 4 is a schematic illustration of a perspective view of the stacked lattice periodic cellular structure of the present invention where the hollow tube or solid ligament arrays are stacked in alternating perpendicular arrays and bonded to form a stacked lattice core and structural panels have been bonded to the exterior of the stacked lattice core at an angle of 45 degrees from the orthogonal edges of the periodic cellular core to form a structural panel.
  • FIG. 5 is a schematic illustration of a perspective view of the stacked pyramidal periodic cellular structure of the present invention where the hollow or solid pyramidal truss elements are bonded to form a pyramidal core and structural panels have been bonded to the exterior of the pyramidal core to form a structural panel.
  • FIG. 6 is a photographic depiction of a side view of the stacked pyramidal periodic cellular structure of the present invention showing the desired bending angle of the pyramidal periodic cellular core.
  • FIG. 7 is a perspective view of the stacked pyramidal periodic cellular structure shown in FIG. 6.
  • FIG. 8 is a schematic illustration of one embodiment of the bending technique used to form the stacked pyramidal periodic cellular structure of the present invention.
  • FIG. 9 is a schematic depiction of a perspective view of a lattice core structure of an embodiment of the present invention where the hollow tube arrays are stacked in alternating perpendicular arrays and bonded to form a stacked lattice core.
  • FIGS. 9(A)-(C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees of one another (90-0 configuration), and about 90 degree configuration with additional vertical rods (90-0 vertical configuration), respectively.
  • FIG. 10 is a photographic depiction of a perspective view of a stacked lattice core structure of the present invention where the hollow tube arrays are stacked in alternating perpendicular arrays and bonded to form a stacked lattice core.
  • FIG. 9 is a schematic depiction of a perspective view of a lattice core structure of an embodiment of the present invention where the hollow tube arrays are stacked in alternating perpendicular arrays and bonded to form a stacked lattice core.
  • FIG. 10(A) illustrates the desire offset angle are shown at about 90 degrees of one another having four planes or layers, along with a substrate (panel) on both face sides.
  • FIG. 10(B) illustrate the desire offset angle are shown at about 0 degrees of one another (generally aligned) having two planes or layers, as well as a partial frame on the left and right side of the lattice core.
  • FIGS H(A)-(E) shows the use of an illustrative and non- limiting brazing process for manufacturing the lattice core structure that may be accomplished by fusing aluminum alloy tubes together to make one cohesive core piece and /or attach it to face plates.
  • the 90 degree configuration also includes the vertical rods configuration (90-0 vertical configuration).
  • FIG. 12 provides a schematic illustration of an embodiment of the lattice structure.
  • ceramics and foams may be inserted into any of the first array, second array, or third array structural elements, etc. to armor the lattice structures 110 from ballistic impacts.
  • FIG. 12(A) provides the foam inserts 131
  • the second FIG. 12(A) provides ceramic inserts 133. It should be appreciated that any combination of material types or compositions may be included as desired or required for the structures, inserts, or panels disclosed herein.
  • the inserts are provided as vertical and/or horizontal inserts.
  • FIG. 13 is a schematic depiction of a perspective view of an embodiment of the lattice core structure of the present invention of hollow tube arrays.
  • FIGS.13(A)- (C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees of one another (0/90 configuration) and about 90 degree configuration with additional vertical rods (90-0 vertical configuration), respectively. Panels, face sheets or substrates are provided on the face or sides of the structure.
  • FIG. 14. provides a schematic illustration of an embodiment of the lattice structure. Within the hollow tubing, ceramics and foams may be inserted to armor the structures from ballistic impacts.
  • FIG. 14(B) provides the foam and/or ceramic inserts.
  • FIGS. 15 shows the use of an illustrative and non- limiting fabrication process for manufacturing an embodiment of the lattice core structure. Steps may be reordered or omitted as desired or required.
  • This fabrication sequence illustrates how square tubes are formed into cellular structures using a dip brazing method followed with a heat treatment process for aluminum.
  • FIGS. 16(A)-(C) are a photographic depiction of two types of elevational views of a lattice core structure of the hollow tube arrays.
  • FIGS. 16(A)-(C) are a photographic depiction of two types of elevational views of a lattice core structure of the hollow tube arrays.
  • 16(A)-(C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees of one another (0/90 configuration), and the 0/90 degree configuration with additional vertical rods (0/90/V), respectively.
  • p/ p s represents relative core density.
  • p is the density of the core p s represents the density of a solid core structure.
  • Panels, face sheets, or substrates are provided on the face or sides of the structure.
  • FIG. 17(A) provides a graphical representation of a quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0-0 core configuration.
  • FIGS. 17(B)-(G) represent the lattice core structure at various percentages of strain, ⁇ , levels.
  • FIG. 18(A) provides a graphical representation of quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0/90 core configuration.
  • FIGS. 18(B)-(G) represent the lattice core structure at various percentages of strain, ⁇ , levels.
  • FIG. 19(A) provides a graphical representation of quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0-90-V core configuration.
  • FIGS. 19(B)-(G) represent the lattice core structure at various percentages of strain, ⁇ , levels.
  • FIG. 20(A) provides a graphical representation of quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0-90-V core configuration.
  • FIGS. 20(B)-(G) represent the lattice core structure at various percentages of strains, ⁇ , levels.
  • FIG. 21 illustrates schematic illustration of a lattice core structure that may be tested by providing the rig that can be operated in a sliding mode to determine the impulse transferred to the core structure.
  • the rig can be operated in a sliding mode to determine the impulse transferred to the test structure (from the height travelled and knowledge of the pendulum mass) or with the Kolsky bars fixed to measure the transmitted pressure waveform.
  • FIG. 22 is a photographic depiction of an elevation view of a lattice core structure of the present invention of hollow tube arrays comprising four layers or planes, as well has having panels, face sheets, or substrates provided on the face or sides of the structure.
  • FIGS.22(A)-(C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees of one another (0/90 configuration), and about 90 degree configuration with additional vertical rods (90-0 vertical configuration), respectively.
  • the lattice cores of FIGS.22(A)-(C) relative core densities of 14.8, 14.3 and 18.6 percent, respectively.
  • FIGS 23(A)-(B) are photographic depictions of elevation views of a lattice core structure of the present invention of hollow tube arrays comprising four layers or planes that have 90 degree configuration with additional vertical rods (0-90 vertical configuration), FIGS.23(A)-(B) represent the lattice core structure subjected to various blast standoff distances. The results from the blast tests were average core strains of 5 percent and 8 percent, respectively, and different standoff distances (24 cm and 19 cm, respectively). Table 1 provides a vertical Rig "Sliding Mode" Specific Impulses (Wet sand) of the an aluminum tube core.
  • Table 2 provides an Impulse Reduction (% Calibration Block) an aluminum tube core.
  • FIGS. 1, 2, 3, and 4 includes a first array of hollow or solid structural elements 1 oriented along a first axis 5 and in a first plane 3.
  • a second array of hollow or solid structural elements 2 oriented along a second axis 6 and in a second plane 4.
  • Bonding techniques for attaching the arrays of hollow or solid structural elements 1, 2 may include: brazing or other transient liquid phases, adhesives, diffusion bonding, resistance welding, electron welding, or laser welding.
  • FIG. 2 shows the first two arrays of hollow or solid structural elements 1, 2 from a top view as well as the contact points 7 where the bonding occurs.
  • FIG. 2 also depicts the offset angle 15 between the first array of hollow or solid structural elements 1 and the second array of hollow or solid structural elements 2. This angle can be varied from 0 to 90 degrees to alter the mechanical properties of the resulting stacked lattice structure 10 shown in FIG. 1, for example.
  • the resulting stacked lattice structure 10 as shown in FIG. 1 is used as a core for the periodic cellular structure of the present invention.
  • wicking elements located along the inner diameter of the arrays of hollow structural elements 1, 2 are wicking elements (not shown) which act to facilitate heat transfer throughout the stacked lattice structure 10.
  • an interconnected cellular or truss network that has hollow ligaments having a triangular or cusp-like shaped cross section, or an acute-angled corner will not require an internal wicking mechanism to effect a heat pipe.
  • the corner regions of the heat pipe act as return channels or groves.
  • the tubes being hollow, additional functionality can be readily integrated into the structures described in this document.
  • the hollow nature of the tubes allow for the structure to become a very lightweight current collector for the integration of power storage devices such as batteries.
  • power storage devices such as batteries.
  • PCT International Application No. PCT/USOl/25158 entitled “Multifunctional Battery and Method of Making the Same,” filed on August 10, 2001, and corresponding US Application No. 10/110,368, filed July 22, 2002, of which are hereby incorporated by reference herein in their entirety, there is provided other ways of forming current collectors.
  • the stacked lattice structure is sandwiched between two parallel structural panels 8 which can be constructed of metal or some non-conductive structural material including polymers or structural composites.
  • the structural panels are affixed to any two parallel exterior surfaces 9 of the stacked lattice structure 10 using any of the bonding techniques listed above for bonding the arrays of hollow structural elements 1,2.
  • the resulting periodic cellular structure is one embodiment of the subject invention.
  • the arrays of hollow structural elements 1, 2 may be circular in cross section.
  • the cross sectional shapes of the hollow structural elements may also be varied in order to change the overall structural properties of the stacked lattice structure 10.
  • Possible cross sectional shapes for the hollow structural elements include: circular, triangular, rectangular, square, and hexagonal.
  • FIGS. 5 and 6 a first array of hollow or solid pyramidal truss elements 12 is oriented along a desired plane or contour.
  • first array of hollow or solid pyramidal truss elements 1 it is possible to stack additional arrays of hollow or solid pyramidal truss elements oriented as desired (not shown).
  • the array of pyramidal truss elements 12 are bonded together at their contact points 7 to serve as the structural core for this embodiment of the subject invention.
  • the truss units may be a variety of truss arrangements such as, but not limited thereto, the following: tetrahedral, pyramidal, three-dimensional Kagome or any combination thereof.
  • bonding techniques for attaching the first array of hollow or solid pyramidal truss elements 12 to a second array or third array and structural panel 8 may include: brazing or other transient liquid phases, adhesives, diffusion bonding, resistance welding, electron welding, or laser welding.
  • the offset angle of the legs or ligaments can be varied from 0 to 90 degrees to alter the mechanical properties of the resultant pyramidal structure 12.
  • the resulting pyramidal structure 12 as shown in FIG. 5 and 6 is used as a core for the periodic cellular structure that is an alternate embodiment of the subject invention.
  • wicking elements located along the inner diameter of the arrays of hollow or solid pyramidal truss elements 12 are wicking elements (not shown) which act to facilitate heat transfer throughout the pyramidal structure 12.
  • the stacked pyramidal structure is sandwiched between two parallel structural panels 8 which can be constructed of metal or some non-conductive structural material including polymers or structural composites.
  • the structural panels are affixed to any two parallel exterior surfaces 9 of the pyramidal structure 12 using any of the bonding techniques listed above for bonding the arrays of hollow pyramidal truss elements 12.
  • FIG. 6 shows a side view of the alternate embodiment of the subject invention where the core of the periodic cellular structure comprising a stacked pyramidal structure 12 bonded to two structural panels 8 along parallel exterior surfaces 9 of the stacked pyramidal structure 12.
  • FIG. 6 also depicts the desired bending angle 16 of the arrays of hollow pyramidal truss elements 12. This desired bending angle 16 can be varied between 0 and 180 degrees to adjust the overall mechanical properties of the stacked pyramidal structure 12.
  • FIG. 7 shows a perspective view of the embodiment the stochastic cellular structure shown in FIG. 6, which comprises a pyramidal structure 12 bonded to two structural panels 8 along parallel exterior surfaces 9 of the pyramidal structure 12.
  • FIG. 7 shows the intertwined solid or hollow ligaments of the stochastic hollow or solid pyramidal truss elements 12.
  • the arrays of hollow or solid pyramidal truss elements 12 may be circular in cross section.
  • the cross sectional shapes of the hollow or solid pyramidal truss elements 12 may also be varied as in the first embodiment in order to change the overall structural properties of the pyramidal structure 12.
  • Possible cross sectional shapes for the hollow pyramidal truss elements 12 include: circular, triangular, rectangular, square, and hexagonal.
  • the first and second arrays of hollow structural elements 1,2 are stacked and bonded at their contact points 7 such that the arrays are aligned at a desired offset angle 15.
  • Bonding techniques may include, but are not limited to, the techniques listed above in the detailed description of the first embodiment of the subject invention.
  • the stacking and bonding steps can be repeated to add and bond further arrays of hollow structural elements until a stacked lattice structure 10 of the desired size is obtained.
  • structural panels 8 can be added to sandwich the stacked lattice structure 10 along parallel exterior surfaces 9 to form a structural panel.
  • the method for producing the alternate embodiment stacked pyramidal structure 12 as shown in FIGS. 5 and 6 begins with the stacking of two arrays of hollow structural elements as shown in FIG. 2.
  • a first array of hollow structural elements 1 is prepared.
  • a second array of hollow structural elements 2 is formed.
  • the two-layer stacked lattice structure is them subjected to a bending operation such that the two layer stacked lattice structure is bent to a desired bending angle 16 as shown in FIG. 6 to form the resulting stacked pyramidal structure 12.
  • FIG. 8 depicts one method of completing the bending step in order to achieve a desired bending angle 16 of the pyramidal structure 12.
  • a wedge-shaped punch 17 is applied in a direction perpendicular to the planes of the first and second arrays of hollow structural elements 1,2 as shown in FIG. 2.
  • the wedge- shaped punch 17 used to bend the two-layer stacked lattice structure into an interlocking die 18 such that the desired bending angle 16 is achieved in the resulting pyramidal structure 12.
  • a press, stamp, or rolling process e.g., passage through a set of saw-toothed rollers
  • An exemplary illustration of an end result is represented by FIGS. 6-7.
  • the embodiments and methods of manufacture for the embodiments described above provide a number of significant advantages.
  • the methods of producing these periodic cellular structures allows for infinite variation in the cross- sectional size and shape of the arrays of hollow and solid structural elements 1,2 and the arrays of hollow and solid pyramidal truss elements 12 that make up the resulting stacked lattice structures 10 and stacked pyramidal structures. This flexibility is accomplished while still allowing for hollow passageways within the arrays of hollow structural elements 1, 2 whereby wicking elements 11 and fluids may be introduced in order to obtain optimum heat transfer performance within the periodic cellular structure.
  • An embodiment of the present invention provides for the best heat transfer properties of open cell stochastic metal foams with the geometric and structural certainty of an engineered truss structure.
  • an embodiment of the subject invention provides for easy construction using a variety of bonding techniques. Where open cell stochastic metal foams require some stretching and temperature processing to achieve the slightest isotropic tendencies, the present invention provides for exacting control over all of the mechanical properties of the resulting periodic cellular structure by adjustment of: the cross sectional shapes of the arrays of hollow structural elements 1,2, the desired offset angle 15 between the first and second arrays l,2and the desired bending angle 16 in the case of the pyramidal structure 12 described above as the alternate embodiment. In addition, the structural rigidity and surface area of the wicking elements contained within the periodic cellular structure by increasing the density of parallel hollow structural elements within the stacked arrays 1,2 and pyramidal truss elements 12.
  • the subject invention provides a way to combine the best heat transfer capabilities of the open cell stochastic metal foam with the structural integrity and predictability of engineered truss shapes in a method that is simple and inexpensive to perform.
  • FIG. 9 shows the use of square tubes to fabricate sandwich panels with variable prismatic to honeycomb topologies.
  • FIG 9(A) provides a structure and is called the 0-0 configuration.
  • the lattice structure 110 provides a first array of structural elements 101 along a first axis 5 in a first plane 3.
  • a second array of hollow or solid structural elements 102 oriented along a second axis 6 and in a second plane 4.
  • the stacked arrays of hollow structural elements 101, 102 are then bonded or affixed together at their respective contact points 107.
  • hollow tubes with square, triangular, hexagonal etc cross sections are laid collinearly on-top of one another. Referring to FIG.
  • the lattice structure 110 provides a first array of structural elements 101 along a first axis 5 in a first plane 3.
  • a second array of hollow or solid structural elements 102 oriented along a second axis 6 and in a second plane 4.
  • the stacked arrays of hollow structural elements 101, 102 are then bonded or affixed together at their respective contact points 107.
  • hollow tubes with square, triangular, hexagonal etc cross sections are laid collinearly on-top of one another.
  • the lattice structure 110 provides a first array of structural elements 101 along a first axis 5 in a first plane 3.
  • a second array of hollow or solid structural elements 102 oriented along a second axis 6 and in a second plane 4.
  • a third array of structural elements 120 is provided substantially vertical to both the first and second array in a third axis 121.
  • the third axis may vary from a range of abut 0 to about 90 degrees.
  • the wall thickness and tube dimensions determine the relative density (volume fraction of core occupied by material) which can be varied from less than 0.01 to near 100%.
  • the figures show the use of identical tubes for the 0°, 90° and vertical elements but we envisage structures in which these are independently varied and structures where the 0 and 90° tubes are removed to create a structure with only vertical tubes.
  • An aspect of various embodiments of the present invention provides the ability to freely vary the component of prismatic to honeycomb fraction to be a novelty of the current invention.
  • An aspect of various embodiments of the present invention also envisages structures where the dimensions and fractions of the three elements of the structure to be spatially varied creating regions within the panel of different mechanical response.
  • FIG. 10 shows photographs of structures that have already been fabricated using the configurations mentioned previously.
  • FIG. 10(A) provides a photograph is in the 0-90 configuration and is used for impulse tests.
  • the core of the structure is 8" X 8" X 3" and 6061-T6 aluminum is the material of choice. It should be appreciated that any available material may be used as desired or required.
  • the 6061-T6 aluminum plates that sandwich the core together measure 3/16" in thickness.
  • the top sandwich plate is greater than 8" X 8" in area, so it can be mounted to the structure shown in FIG. 21.
  • FIG. 10(B) provides a photograph is a 21.75" X 21.75" structure. It is in the 0-0 configuration and will be used for blast tests. This structure may be sandwiched between two face sheets of aluminum, but this photograph was intended to show the specifics of the core.
  • Example No. 3 The tube core structures can be made by any joining process including adhesive bonding, brazing, numerous welding techniques, diffusion bonding, etc.
  • the following schematic, Fig 11, shows the use of a general dip brazing process that can be used to fuse aluminum alloy tubes together and make one cohesive core piece and /or attach it to face plates.
  • Example No. 4 The interior of the tubes and/or the open spaces between the tubes can be filled or partially filled with other materials to create desirable panel properties. For example, they can be filled with polymer, metal or ceramic foams. They can also be filled powder particles, fibers or composites of these various materials.
  • the two schematic figures shown in Figure 12 provide two examples of these configurations.
  • ceramics and foams may be inserted to armor the structures from ballistic impacts.
  • Figure 12(A) provides foam inserts
  • Figure 12(B) provides ceramic inserts.
  • the various figures schematically show, among other things, the type of lattice structures that are being designed.
  • the lattice core incorporates hollow rods in three different geometries.
  • 6061 -T6 aluminum has been used to fabricate the cores.
  • many numerous metals may be used to create these cores.
  • These cores may be fused together through a dip brazing process as shown.
  • the core structure is held together between two face sheets made of the same material as the cores.
  • the hollow square core on its own should provide resistance to explosive blasts. By inserting anti-ballistic materials such as ceramics and foams, may make this structure resistant to ballistic penetration.
  • FIG. 13 is a schematic depiction of a perspective view of an embodiment of the lattice core structure of the present invention of hollow tube arrays.
  • FIGS.13(A)- (C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees of one another (0/90 configuration) and about 90 degree configuration with additional vertical rods (90-0 vertical configuration), respectively. Panels, face sheets or substrates are provided on the face or sides of the structure.
  • FIG. 14 provides a schematic illustration of an embodiment of the lattice structure.
  • ceramics and foams may be inserted to armor the structures from ballistic impacts.
  • FIG. 14(B) provides the foam and/or ceramic inserts. It should be appreciated that any combination of material types or compositions may be included as well for the inserts or structures.
  • the inserts are provided as vertical and/or horizontal inserts.
  • FIGS 15 shows the use of an illustrative and non- limiting fabrication process for manufacturing an embodiment of the lattice core structure. Steps may be reordered or omitted as desired or required. This fabrication sequence illustrates how square tubes are formed into cellular structures using a dip brazing method followed with a heat treatment process for aluminum.
  • FIGS. 16(A)-(C) are a photographic depiction of two types of elevational views of a lattice core structure of the hollow tube arrays.
  • FIGS. 16(A)-(C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees of one another (0/90 configuration), and the 0/90 degree configuration with additional vertical rods (0/90/V), respectively.
  • p/ p s represents relative core density.
  • p is the density of the core p s represents the density of a solid core structure.
  • Panels, face sheets, or substrates are provided on the face or sides of the structure.
  • a frame or partial frame may be provided along any of the four edges.
  • FIG. 17(A) provides a graphical representation of a quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0-0 core configuration.
  • FIGS. 17(B)-(G) represent the lattice core structure at various percentages of strain, ⁇ , levels.
  • FIG. 18(A) provides a graphical representation of quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0/90 core configuration.
  • FIGS. 18(B)-(G) represent the lattice core structure at various percentages of strain, ⁇ , levels.
  • FIG. 19(A) provides a graphical representation of quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0-90-V core configuration.
  • FIGS. 19(B)-(G) represent the lattice core structure at various percentages of strain, ⁇ , levels.
  • FIG. 20(A) provides a graphical representation of quasi-static representation of Stress, ⁇ versus Strain, ⁇ for 0-90-V core configuration.
  • FIGS. 20(B)-(G) represent the lattice core structure at various percentages of strains, ⁇ , levels.
  • FIG. 21 illustrates schematic illustration of a lattice core structure that may be tested by providing the rig that can be operated in a sliding mode to determine the impulse transferred to the core structure.
  • the rig can be operated in a sliding mode to determine the impulse transferred to the test structure (from the height travelled and knowledge of the pendulum mass) or with the Kolsky bars fixed to measure the transmitted pressure waveform.
  • FIG. 22 is a photographic depiction of an elevation view of a lattice core structure of the present invention of hollow tube arrays comprising four layers or planes, as well has having panels, face sheets, or substrates provided on the face or sides of the structure.
  • FIGS.22(A)-(C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees of one another (0/90 configuration), and about 90 degree configuration with additional vertical rods (90-0 vertical configuration), respectively.
  • the lattice cores of FIGS.22(A)-(C) relative core densities of 14.8, 14.3 and 18.6 percent, respectively.
  • Example No. 15 is a photographic depiction of an elevation view of a lattice core structure of the present invention of hollow tube arrays comprising four layers or planes, as well has having panels, face sheets, or substrates provided on the face or sides of the structure.
  • FIGS.22(A)-(C) illustrate the desire offset angle are shown at about 0 degrees (0-0 configuration), about 90 degrees
  • FIGS 23(A)-(B) are photographic depictions of elevation views of a lattice core structure of the present invention of hollow tube arrays comprising four layers or planes that have 90 degree configuration with additional vertical rods (0-90 vertical configuration), FIGS.23(A)-(B) represent the lattice core structure subjected to various blast standoff distances. The results from the blast tests were average core strains of 5 percent and 8 percent, respectively, and different standoff distances (24 cm and 19 cm, respectively).
  • any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. Unless clearly specified to the contrary, there is no requirement for any particular described or illustrated activity or element, any particular sequence or such activities, any particular size, speed, material, dimension or frequency, or any particularly interrelationship of such elements. Accordingly, the descriptions and drawings are to be regarded as illustrative in nature, and not as restrictive. Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. When any range is described herein, unless clearly stated otherwise, that range includes all values therein and all sub ranges therein.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne des structures en panneaux sandwich comprenant des âmes cellulaires légères utilisées pour supporter efficacement les contraintes qui soumettent le panneau à des déformations de flexion ou de flambage. Des panneaux similaires présentant une résistance élevée et/ou d’importantes déformations de tassement se prêtent également à une utilisation pour l’atténuation d’impacts et d’effets de souffle. Des panneaux dans lesquels les espaces cellulaires à l’intérieur de l’âme sont constitués de matériaux de résistance balistique entravent en outre la pénétration des projectiles. De plus, ils pourraient être utilisés pour contenir, par exemple, les fragments créés par la désintégration d’un moteur ou ceux créés par une explosion.
PCT/US2009/034690 2008-02-20 2009-02-20 Procédé de fabrication d’une structure cellulaire et structure cellulaire résultante WO2009105651A2 (fr)

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US61/030,051 2008-02-20

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WO2013087370A3 (fr) * 2011-12-12 2013-10-24 Renco World Corporation Élément de support utilisé dans des éléments de structure
US9745736B2 (en) 2013-08-27 2017-08-29 University Of Virginia Patent Foundation Three-dimensional space frames assembled from component pieces and methods for making the same
US10107560B2 (en) 2010-01-14 2018-10-23 University Of Virginia Patent Foundation Multifunctional thermal management system and related method
US10184759B2 (en) 2015-11-17 2019-01-22 University Of Virgina Patent Foundation Lightweight ballistic resistant anti-intrusion systems and related methods thereof
US10378861B2 (en) 2014-09-04 2019-08-13 University Of Virginia Patent Foundation Impulse mitigation systems for media impacts and related methods thereof

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US4223053A (en) * 1978-08-07 1980-09-16 The Boeing Company Truss core panels
US20050202206A1 (en) * 2002-05-30 2005-09-15 Wadley Haydn N.G. Method for manufacture of periodic cellular structure and resulting periodic cellular structure
US20080006353A1 (en) * 2002-05-30 2008-01-10 University Of Virginia Patent Foundation Active energy absorbing cellular metals and method of manufacturing and using the same

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JPH0849342A (ja) * 1994-08-04 1996-02-20 Tooami:Kk 建築用などのパネル

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US4223053A (en) * 1978-08-07 1980-09-16 The Boeing Company Truss core panels
US20050202206A1 (en) * 2002-05-30 2005-09-15 Wadley Haydn N.G. Method for manufacture of periodic cellular structure and resulting periodic cellular structure
US20080006353A1 (en) * 2002-05-30 2008-01-10 University Of Virginia Patent Foundation Active energy absorbing cellular metals and method of manufacturing and using the same

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10107560B2 (en) 2010-01-14 2018-10-23 University Of Virginia Patent Foundation Multifunctional thermal management system and related method
WO2013087370A3 (fr) * 2011-12-12 2013-10-24 Renco World Corporation Élément de support utilisé dans des éléments de structure
US9745736B2 (en) 2013-08-27 2017-08-29 University Of Virginia Patent Foundation Three-dimensional space frames assembled from component pieces and methods for making the same
US10378861B2 (en) 2014-09-04 2019-08-13 University Of Virginia Patent Foundation Impulse mitigation systems for media impacts and related methods thereof
US10184759B2 (en) 2015-11-17 2019-01-22 University Of Virgina Patent Foundation Lightweight ballistic resistant anti-intrusion systems and related methods thereof

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