Multifunctional Periodic Cellular Solids and the Method of Making the Same

Abstract

Methods of making truss-based periodic cellular solids that have improved structural properties and multifunctional design. Many materials (metals, ceramics, glasses, polymers, composites and even semiconductors) can be shaped into cellular, truss-like architectures with open, closed or mixed types of porosity and then very uniformly arranged in controlled, three-dimensional space-filling arrays. The truss-like elements do not necessarily have a constant cross-section, nor are they necessarily straight or solid throughout (they could be hollow). Their cross sections can be circular, square, triangular, I-beam or other shapes of interest depending on multifunctional needs. When bonded together by solid state, liquid phase, pressing or other methods at points of contact, a cellular structure of highly repeatable cell geometry and few imperfections results. The bonds hold the truss elements together in a desired configuration, allow load to be efficiently transferred amongst them and make the resulting structure significantly more rigid when bent, compressed or sheared. These constructed cellular solids offer a broad range of multifunctional structural uses with a tremendous freedom for choosing the truss type, orientation and distribution. Multiple materials can be intermixed.

1 . A plate or strip structure comprising:
 N number (N>1) of vertically stacked three-dimensional space filling layers, wherein each of said three-dimensional space filling layers comprise:   an array of elongated plates or strips, each of said plates or strips being substantially planar and including a first side and second side, a first lateral edge and a second lateral edge, and a first longitudinal edge and a second longitudinal edge, and wherein at least some of said plates or strips have slotted apertures partially extending across said sides in a lateral direction;   said plates or strips intersecting with other respective plates or strips, wherein said slotted apertures at least partially allow said intersecting plates or strips to intersect therethrough so as to define an intersection segment; and   wherein at least some of said intersection segments are discretely bonded, wherein said discrete bonds are formed between said intersecting plates or strips   said three-dimensional space filling layers having a top side and a bottom side;   at least a portion of said top side of each of said three-dimensional space filling layers for the first through (N th −1) layers comprises a top adjoining region;   at least a portion of said bottom side of each of said three-dimensional space filling layers for the second through (N th ) layers comprises a bottom adjoining region; and   wherein each of said three-dimensional space filling layers are discretely bonded to immediate vertically adjacent said three-dimensional space filling layers, wherein said discrete bonds are formed between the said top adjoining region and bottom adjoining region.   
     
     
         2 . The plate or strip structure of  claim 1 , further comprising:
 a perimeter-oriented face sheet having an inner surface and an outer surface, wherein said inner surface is fixedly bonded to a perimeter side of at least a minority of each of said three-dimensional space filling layers.   
     
     
         3 . The plate or strip structure of  claim 2 , further comprising:
 a second perimeter-oriented face sheet having an inner surface and an outer surface, wherein said inner surface is fixedly bonded to a second one of said perimeter sides of at least a minority of each of said three-dimensional space filling layers.   
     
     
         4 . The plate or strip structure of  claim 3 , further comprising:
 a third perimeter-oriented face sheet having an inner surface and an outer surface, wherein said inner surface is fixedly bonded to a third one of said perimeter sides of at least a minority of each of said three-dimensional space filling layers; and   a fourth perimeter-oriented face sheet having an inner surface and an outer surface, wherein said inner surface is fixedly bonded to a fourth one of said perimeter sides of at least a minority of each of said three-dimensional space filling layer   
     
     
         5 . The plate or strip structure of  claim 1 , further comprising:
 a layer-oriented face sheet having an inner surface and an outer surface, wherein said inner surface is fixedly bonded to at least a portion of said bottom side of first said three-dimensional space filling layer.   
     
     
         6 . The plate or strip structure of  claim 5 , further comprising:
 a second layer-oriented face sheet having an inner surface and an outer surface, wherein said inner surface is fixedly bonded to at least a portion of said top side of N th  said three-dimensional space filling layer.   
     
     
         7 . The plate or strip structure of  claim 1 , wherein said truss structure is curved. 
     
     
         8 . A method of making a plate or strip structure comprising:
 providing N number (N>1) of three-dimensional space filling layers, wherein each of said three-dimensional space filling layers comprise:   an array of elongated plates or strips, said plates or substantially planar including a first side and second side, a first lateral edge and a second lateral edge, and a first longitudinal edge and a second longitudinal edge, and wherein some of said plates or having slotted apertures partially extending across said sides in a lateral direction;   said plates or strips intersecting with other respective plates or strips, wherein said slotted apertures at least partially allow said intersecting plates or strips to intersect therethrough so as to define an intersection segment; wherein at least some of said intersection segments are discretely bonded;   said three-dimensional space filling layers having a top side and a bottom side;   contacting each of said three-dimensional space filling layers with immediate vertically adjacent three-dimensional space filling layers at respective said top adjoining region and said bottom adjoining region; and   joining each of said contacted three-dimensional space filling layers by forming a bond at said areas of contact.   
     
     
         9 . The method of  claim 8 , further comprising:
 providing a perimeter-oriented face sheet having an inner surface and an outer surface;   bonding said inner surface to a perimeter side of at least a minority of each of said three-dimensional space filling layers.   
     
     
         10 . The method of  claim 9 , further comprising:
 providing a second perimeter-oriented face sheet having an inner surface and an outer surface;   bonding said inner surface to a second one of said perimeter sides of at least a minority of each of said three-dimensional space filling layers.   
     
     
         11 . The method of  claim 10 , further comprising:
 providing a third perimeter-oriented face sheet having an inner surface and an outer surface;   bonding said inner surface to a third one of said perimeter sides of at least a minority of each of said three-dimensional space filling layers;   providing a fourth perimeter-oriented face sheet having an inner surface and an outer surface; and   bonding said inner surface to a fourth one of said perimeter sides of at least a minority of each of said three-dimensional space filling layers.   
     
     
         12 . The method of  claim 8 , further comprising:
 providing a layer-oriented face sheet having an inner surface and an outer surface; and   bonding said inner surface to at least a portion of said bottom side of first said three-dimensional space filling layer.   
     
     
         13 . The method of  claim 12 , further comprising:
 providing a second layer-oriented face sheet having an inner surface and an outer surface; and   bonding said inner surface to at least a portion of said top side of N th  said three-dimensional space filling layer.