Method of manufacturing component for manipulating input shock wave

Abstract

A method (100) of manufacturing a component (1) for manipulating input shock waves. The method comprises: forming a plurality of plates (31), each plate defining a sub-cavity (50); at least partially filling one or more of the sub-cavities (50) with one or more cavity filling materials (207); and stacking the plurality of plates (31) to form the component (1) such that the sub-cavities (50) are at least partially aligned and the sub-cavities (50) combine to define a layered component cavity (205) containing one or more cavity filler materials (207).

Description

[0001] The present invention relates to a method of making a component for manipulating an input shock wave, and more particularly to a method of making a component to be used in a method and apparatus for producing a high local energy concentration.

[0002] It has been shown in WO 2011 / 138622 that the interaction between the shock wave in the non-gaseous medium and the gaseous medium can generate a high-speed lateral jet of the non-gaseous medium moving through the gaseous medium. This causes the jet to hit and capture a certain volume of the gaseous medium (e.g., hit a target), thus generating a strong energy concentration in the gas.

[0003] The present invention seeks to provide a method of manufacturing a component for use in an alternative technology for producing localized energy concentration.

[0004] Viewed from a first aspect, the invention provides a method of manufacturing a component for manipulating an input shock wave, the method comprising:

[0005] forming a plurality of plates, each plate defining a subcavity;

[0006] at least partially filling one or more of the subcavities with one or more cavity-filling materials; and

[0007] The plurality of sheets are stacked to form a component such that the subcavities are at least partially aligned and the subcavities combine to define a layered component cavity containing the one or more cavity filling materials.

[0008] Thus, the present invention provides a method of manufacturing a component that manipulates a shock wave when the shock wave is incident on the component. The component cavity preferably includes (defines) an input end (e.g., an orifice) arranged to receive an (input) shock wave incident on the input end of the cavity. The component cavity is arranged (e.g., shaped) to manipulate the shock wave when the shock wave passes through the component cavity. The component cavity preferably includes (defines) an output end (e.g., an orifice) arranged to output the manipulated shock wave.

[0009] The plates are formed of (comprising, e.g. consisting of) a first material. One or more of the sub-cavities contain (e.g. at least partially filled with) a second material, which is a cavity filling material. Thus, the cavity (the shape of the cavity) is defined by the plates (e.g. the inner walls of the plates) (formed of the first material), and the cavity filling material is located within the volume of the cavity.

[0010] It can be seen that due to the difference in the impact impedance of the cavity (e.g., the shape of the cavity) and the first material and the second material, the component can be used to manipulate the input shock wave (e.g., modify its shape and / or strength). Thus, the (e.g., energy) intensity of the shock wave transmitted from the output end of the cavity can be greater than the (e.g., energy) intensity of the input shock wave received at the input end of the cavity.

[0011] The method includes filling one or more (e.g., all or a subset) of the subcavities (e.g., partially filling or completely filling the volume defined thereby) with one or more (e.g., a single or multiple different) cavity filling materials. Preferably, the step of filling one or more of the subcavities with the one or more cavity filling materials is performed before the step of stacking the plurality of plates to form the component.

[0012] The method includes stacking (e.g., arranging in parallel) the plurality of plates to form a component such that the subcavities are at least partially aligned (e.g., overlapping) and combine to define a layered component cavity (e.g., an entire cavity consisting of layers, each layer being defined by a subcavity) containing the one or more cavity filling materials. Preferably, the step of stacking the plurality of plates to form the component is performed after the step of filling one or more of the subcavities with the one or more cavity filling materials.

[0013] Components having layered component cavities can be formed by forming a monolithic body, milling the body to form the cavity, and then fitting the layers into the cavity. However, for components of relatively small size (e.g., on the order of millimeters or less), forming the component in this manner so that the tolerances between the layers themselves and between the layers and the cavity walls are acceptable is difficult. Small imperfections in the component are undesirable because they can significantly affect the way the component manipulates the input shock wave (e.g., modify the shape and / or intensity of the input shock wave).

[0014] Fabricating and assembling components from a stack of discrete boards helps allow layered component cavities to be formed more easily and with greater manufacturing accuracy. Further, being able to disassemble components helps with quality assurance and testing purposes.

[0015] In an embodiment, one or more (e.g., all or a subset) of the plurality of panels are formed from (comprising, e.g., consisting of) a high-density material (e.g., a material having a high impact impedance such that the material substantially reflects input shock waves).

[0016] In an embodiment, one or more of these sub-cavities extend through the entire depth of the respective plate (e.g., extending from one surface of the plate to an opposite surface of the plate). In an embodiment, one or more of these sub-cavities do not extend through the entire depth of the respective plate (e.g., the sub-cavities are formed as recesses or notches in the respective plate).

[0017] In an embodiment, one or more (eg, all or a subset) of the plurality of plates are formed of (including, eg, consist of) a (eg, transition) metal.

[0018] In an embodiment, one or more (eg, all or a subset) of the plurality of plates are formed of (including, eg, consist of) a heavy metal (eg, tantalum, tungsten, copper, steel, or platinum).

[0019] In embodiments, the or each cavity filling material has a density (e.g., shock impedance) that is lower than the density of one or more (e.g., all) of the plurality of panels. Thus, the shape and / or intensity of an input shock wave may be manipulated by the component cavity, as the shock wave may be reflected longitudinally from boundaries between sub-cavities and / or panels, and also laterally from cavity walls (at the edges of the sub-cavities).

[0020] In an embodiment, the method comprises filling one or more (eg, all or a subset) of the sub-cavities with plastic material (eg, partially filling or completely filling the volume defined thereby).

[0021] The subcavities may be filled using any suitable manufacturing method, such as additive manufacturing or injection molding.

[0022] In embodiments, the method includes filling one or more (e.g., all or a subset) of the subcavities (e.g., partially filling or completely filling the volume defined thereby) with a castable material (e.g., plastic in liquid form), and then, for example, curing (e.g., hardening) the castable material. In embodiments, curing the castable material may include exposing the castable material to UV light. In embodiments, curing the castable material may include exposing the castable material to heat (e.g., from an oven or from a heat gun).

[0023] Filling one or more cavities with a castable material helps the cavity filling material precisely conform to the shape of the subcavity. Further, forming the part by layers and filling one or more subcavities individually helps alleviate difficulties associated with deep layers of castable material, such as the formation of bubbles during casting, or the inability of UV light to penetrate the entire depth of the castable material, resulting in uneven curing of the castable material.

[0024] In embodiments, one or more sub-cavities (e.g., all or a subset of the sub-cavities) are overfilled (e.g., the volume of cavity filling material exceeds the volume of the sub-cavity). Thus, preferably, the method comprises overfilling one or more sub-cavities. Preferably, the method comprises milling (e.g., filing, grinding, planing, lasering) a surface of one or more of the plurality of plates to remove excess material (e.g., to remove excess (sub-)cavity filling material and excess plate material) and smoothing the surfaces of the plates (e.g., to remove surface imperfections).

[0025] In an embodiment, forming the plates may include forming the plates slightly thicker than the desired final dimension (dimension perpendicular to the plane of the plates). Preferably, the plates (the first material of the plates) are milled away together with, for example, excess cavity filling material. This helps to improve the quality of the surface finish. Since the cavity filling material is milled away together with the material of the plates themselves, this helps to avoid steps at the edges of the sub-cavities.

[0026] The castable material may comprise any suitable material, but in an embodiment, the castable material comprises a castable plastic material, such as polymethylmethacrylate (PMMA) or epoxy.

[0027] The invention also extends to a component manufactured according to the method outlined herein. It will be appreciated that any (eg, optional and preferred) features outlined herein in relation to the method also apply to the component, and vice versa, where applicable.

[0028] In an embodiment, the component cavity includes an input end (e.g., an orifice) for receiving (e.g., designed to receive) (input) a shock wave, and an output end (e.g., an orifice) for outputting (e.g., designed to output) the shock wave, and wherein the shape of the component cavity is configured (e.g., the shapes and arrangements of the sub-cavities are configured relative to each other) such that a cross-sectional area of ​​the input end is larger than a (e.g., corresponding) cross-sectional area of ​​the output end.

[0029] The cross-sectional area of ​​the input and / or output may be defined in a plane that is substantially perpendicular to the direction between the input and output, e.g. such that the cross-sectional area of ​​the input is substantially parallel to the cross-sectional area of ​​the output. The direction between the input and output may be substantially parallel to the direction along which the input shock wave is arranged to propagate to be incident on the component (e.g., in embodiments of the invention).

[0030] In an embodiment, each subcavity has an input end (e.g., an orifice) for receiving shock waves and an output end for outputting shock waves, and wherein one or more of the subcavities are shaped such that the cross-sectional area of ​​the input end is larger than the cross-sectional area of ​​the output end.

[0031] The plates may comprise any suitable and desired shape (e.g., having (inner) walls of such shape) to define the subcavities. In an embodiment, one or more (e.g., all or a subset) of the subcavities comprise a frustum, e.g., one or more plates are shaped to define a frustum-shaped subcavity.

[0032] The frustum may comprise any suitable and desired type of frustum. In an embodiment, one or more of the sub-cavities comprise a conical frustum. Thus, preferably, one or more (e.g., all or a subset) of these sub-cavities are rotationally symmetric about an axis passing through the sub-cavity. Preferably, the axis of the plate or sub-cavity is parallel to the direction between the input and output ends.

[0033] In an embodiment, one or more sub-cavities (cross-sections and / or walls of the one or more sub-cavities) include two or more segments that are at different respective angles to an axis of the sub-cavity (e.g., an axis of rotational symmetry of the sub-cavity, e.g., an axis parallel to a direction between an input end and an output end). Thus, for example, the one or more sub-cavities may include two or more frustums (e.g., sharing a common axis), wherein the two or more frustums have sidewalls that are at different respective angles to the axis of the sub-cavity. Providing different angles may help manipulate the input shock wave in a particular manner, e.g., to accelerate the input shock wave from the input end to the output end.

[0034] In embodiments where one or more subcavities have three or more frustum segments, each segment may be at a different angle than each of the other segments; however, two or more of the segments may be at the same angle, with one or more intermediate segments of the subcavity being at a different angle.

[0035] In embodiments, instead of or in addition to one or more sub-cavities having one or more straight-sided segments (in cross-section), the cross-section of one or more sub-cavities may have segments with one or more curved walls. For example, one or more sub-cavities may include a trumpet-shaped (e.g., conical) frustum in which the sub-cavity walls (e.g., elliptical) are curved. These types of shapes may help make the impact front and impact shape more uniform at the output end.

[0036] In an embodiment, two or more of the plurality of plates include one or more alignment holes (e.g., through holes) configured to (e.g., have a size and shape designed to) receive an alignment member (e.g., a pin), and the method includes aligning the two or more plates by placing the one or more alignment members through the one or more alignment holes.

[0037] In an embodiment, two or more of the plurality of plates include one or more fastening holes (e.g., through holes) configured (e.g., sized and shaped) to receive fastening members (e.g., rods or bolts), and the method includes securing the two or more plates together by placing the one or more fastening members through the one or more fastening holes. Fastening the two or more plates together using fastening members through the fastening holes in the plates helps secure the plates together while also helping maintain alignment of the plates relative to each other.

[0038] In alternative embodiments, the plurality of panels may be secured together in other ways, such as by clamping or using an adhesive.

[0039] The plurality of plates may have any suitable and desired thickness (the dimension perpendicular to the plane extending the plates and parallel to each other). For example, each of the plurality of plates has the same thickness. In an embodiment, the plurality of plates (eg, each) have different thicknesses.

[0040] In an embodiment, the thickness of the plurality of plates (eg, plates defining the subcavities) decreases (eg, gradually) from the input end to the output end.

[0041] Each (e.g., every) plate forming the component may define a subcavity. However, in an embodiment, the plurality of plates (each defining a subcavity) are a plurality of first plates, and the method further comprises forming one or more second plates that do not include (e.g., define) a subcavity, and stacking (e.g., arranging in parallel) the second plates with the first plates.

[0042] In an embodiment, the second plates are formed of (comprise, eg consist of) the same material as the first plates (eg, a heavy metal such as tantalum, platinum, copper, steel or tungsten).

[0043] In an embodiment, the plurality of first plates and the one or more second plates are stacked such that the plates alternate between first plates and second plates, for example, a first plate (each of the one or more) is adjacent to two second plates (sandwiched between the two second plates) and / or a second plate (each of the one or more) is adjacent to two first plates (sandwiched between the two first plates). This creates a component cavity that accommodates a plurality of parallel layers that alternate between layers of cavity filling material and layers of second plate material.

[0044] Providing multiple parallel layers within the component cavity helps to superimpose the components of the input shock wave reflected from the boundaries between the parallel layers. This helps to amplify the intensity of the shock wave between the input end and the output end of the component cavity.

[0045] Although in this embodiment, each sub-cavity is separated from an adjacent sub-cavity by a second plate, it should be understood that the sub-cavities are still combined to form a combined component cavity, because the effect of the component cavity on the input shock wave may still be the same as when the body is formed as a single piece defining an overall cavity, and then the cavity is filled with multiple parallel layers (for example, including a layer of cavity filling material and a layer of second plate material).

[0046] The one or more second plates can have any suitable and desired thickness (the dimension extending perpendicular to the second plates and parallel to the planes of the first plates). For example, each of the second plates has the same thickness. In an embodiment, the one or more second plates (e.g., each) have different thicknesses. The thickness of one or more (e.g., all) (e.g., each) of at least one second layer is greater than the thickness of one or more (e.g., all) (e.g., each) of at least one first layer.

[0047] In embodiments where the plurality of parallel layers comprises a plurality of first layers and / or a plurality of second layers, each of the plurality of first layers may have the same thickness and / or each of the plurality of second layers may have the same thickness, preferably wherein the thickness of the plurality of second layers (e.g. each) is greater than the thickness of the plurality of first layers (e.g. each). In embodiments, the thickness of the plurality of second plates decreases (e.g. gradually) from the input end to the output end.

[0048] The component can have any suitable and desired size, and these sizes will be determined by the specific application of the component. In one embodiment, the thickness, diameter and / or maximum dimension of the component (e.g., the layered component cavity of the component) is between 0.1 mm and 100 mm, such as between 1 mm and 50 mm, such as between 2 mm and 10 mm, such as about 3 mm, 5 mm or 8 mm.

[0049] It should be understood that the term "shock impedance" as used herein is intended to mean "the pressure that must be applied to a medium in order to impart a unit particle velocity to some portion of the medium" (Henderson, "On the refraction of shock waves," Journal of Fluid Mechanics, Vol. 198, January 1989, pp. 365-386). It is equal to the product of the impact velocity and the density of the unimpeded material.

[0050] It will be appreciated that the input shock wave may be formed external to the component (e.g., an element of the component) and propagate into the component, but may additionally or alternatively be generated in the component, for example, by the component (e.g., an element of the component) being impacted (e.g., impacted by a projectile). Both alternatives are encompassed by the phrase "input shock wave".

[0051] Embodiments of the component may be suitable for manipulating (e.g., amplifying) shock waves (e.g., to generate localized energy concentrations) with the goal of generating conditions suitable for nuclear fusion. However, the component is not limited thereto and may be used for other applications, such as testing of safety equipment (e.g., crash helmets). In one example, the component may be used to provide an impact shock wave for testing an impact force damping and dissipation structure as shown in US 10,653,193 B2.

[0052] Certain embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0053] Figure 1 shows a perspective cutaway view of a component for manipulating an input shock wave that has not been manufactured using the method according to the invention;

[0054] Figure 2 shows a perspective cross-sectional view of a component for manipulating an input shock wave manufactured using a method according to an embodiment of the present invention;

[0055] Figure 3 Shows the combination Figure 2 a system of components;

[0056] Figure 4 Shows Figure 2 A three-dimensional cross-sectional view of a single layer of a component;

[0057] Figure 5 Shows Figure 2 A perspective cutaway view of another single layer of the component;

[0058] Figure 6 Shown in exploded view Figure 2 The components of the plate;

[0059] Figure 7 A flow chart illustrating a method according to one embodiment of the present invention is shown;

[0060] Figure 8 Shows Figure 2 variants of the components; and

[0061] Fig. 9 Shows Figure 2 Another variation of the component.

[0062] Methods of making components for manipulating an input shock wave (eg, creating a localized concentration of energy from an input shock wave) will now be described.

[0063] Figure 1A perspective cutaway view of a component 201 for generating a localized energy concentration from an input shock wave is shown. The component 201 includes a body 203 defining a component cavity 205 in the shape of a hollow conical frustum having a cavity wall 206. The body 203 is formed of a material having a high impact impedance. The cavity 205 contains a cavity filling material 207 having a low impact impedance. The impact impedance of the cavity filling material 207 is lower than the impact impedance of the body 203. Within the cavity 205, a plurality of parallel high impact impedance layers 232 are provided. The plurality of high impact impedance layers 232 separate the cavity filling material 207 into a plurality of low impact impedance layers 230.

[0064] The body 203 may be formed from tantalum, but the body may be formed from any suitable material, for example any other suitable (heavy) metal, such as platinum, copper, steel or tungsten.

[0065] In an exemplary embodiment, the cavity filling material 207 is polymethyl methacrylate (PMMA), but the cavity filling material 207 may be any suitable material.

[0066] The component 1 can be formed by milling the body 203 to form the cavity 205, and then fitting the low impact impedance layer 230 and the high impact impedance layer 232 into the cavity 205. However, due to the small size (e.g., on the order of millimeters or less), it is difficult to form the component 201 in this manner so that the tolerances between the layers themselves and between the layers and the cavity wall 206 are acceptable. Further, it is difficult to put the high impact impedance layer into place without deforming or breaking it. Small imperfections in the component 201 are undesirable because they can significantly affect the way the component handles input shock waves.

[0067] Figure 2 shows a basically similar Figure 1 A perspective cross-sectional view of a component 1 shown but formed from multiple layers. Thus, according to an embodiment of the invention, the component is not formed as a body having a cavity which is then filled with layers (e.g. Figure 1 201 shown). Rather, the component is manufactured and assembled as a stack of discrete layers that, when combined, form a Figure 1 Essentially the same cavity is shown, but manufactured with greater accuracy.

[0068] exist Figure 2In the embodiment of , the low impact impedance layer 30 is formed by a sub-cavity defined by a first plate 31, and the high impact impedance layer 32 is formed as a second plate 32. Both the first plate 31 and the second plate 32 span the cross-sectional area of ​​the component 1, but the first plate 31 each defines a sub-cavity 50, while the second plate 32 is solid. Therefore, the body 3 itself is formed by parallel layers. The component cavity 5 has an input end 9 configured to receive a shock wave, and an output end 11 configured to output the shock wave after the shock wave has propagated through the component 1. The cross-sectional area of ​​the input end 9 is larger than the cross-sectional area of ​​the output end 11. Similarly, as can be seen from Figure 4 It can be seen that each sub-cavity has an input end 509 and an output end 511, and the cross-sectional area of ​​the input end 509 of each sub-cavity 50 is larger than the cross-sectional area of ​​the output end 511 of the sub-cavity 50. In the illustrated embodiment, each sub-cavity 50 is shaped as a conical frustum.

[0069] The component 1 itself has an input face 10 close to the input end 9 of the cavity 5 , and an output face 12 close to the output end 11 of the cavity 5 .

[0070] The cavity 5 is filled with a low impact impedance layer 30 formed of a low impact impedance cavity filling material 7 (PMMA in the illustrated embodiment), and a high impact impedance layer 32 formed of a high impact impedance material (tantalum in the illustrated embodiment) plate. The high impact impedance layer 32 is formed of a material having an impact impedance higher than that of the material forming the low impact impedance layer 30.

[0071] Although in the illustrated embodiment, each sub-cavity 50 is separated from adjacent sub-cavities 50 by second plates 33, it should be understood that the sub-cavities 50 are still combined to form a combined component cavity 5, and since the component cavity 5 is still formed as a single piece with the body to define an overall cavity due to its effect on the input shock wave, the cavity is then filled with a plurality of parallel layers (e.g., as shown in Figure 1) alternating between high impact impedance layers and low impact impedance layers. Figure 1 The effect is the same as shown).

[0072] The parallel layers alternate layer by layer from low impact impedance layers 30 to high impact impedance layers 32. In the illustrated embodiment, the input layer 34 forming the input face 10 of the component 1 is a low impact impedance layer 30. This is because an input face 10 formed of a high impact impedance layer 32 would result in a greater portion of the shock wave being reflected by the input face 10 and therefore not transmitted into the component 1. However, alternatives are contemplated.

[0073] In the illustrated embodiment, the high impact impedance layer 32 and the low impact impedance layer 30 decrease in thickness from the input face 10 to the output face 12, except for the input layer 34. It should be understood that while the thickness may vary between layers, each individual layer has a uniform thickness across its width.

[0074] Now refer to Figure 3 The operation of component 1 is explained. Input terminal 9 is configured to receive a shock wave. Figure 3 In the embodiment shown, the shock wave is generated by impacting the input face 10 of the component 1 with a disc-shaped projectile 13. This impact generates a planar shock wave in the component 1, which is focused by the component 1 onto the target 15, thereby generating a local energy concentration at the location of the target 15.

[0075] When input into the cavity 5, the input shock is reflected from the cavity wall 6 as irregular shock reflections (Mach reflections), which propagate inwardly from the cavity wall 6 and eventually overlap on the central axis of the cavity 5. The overlap of the radially symmetric waves on the central axis creates a high pressure point in the cavity filling material 7, which expands and interacts with the impinging Mach reflections, thereby generating an axial quasi-planar Mach rod that propagates toward the output end 11 of the cavity 5.

[0076] The layers 30, 32 are arranged so that a shock wave generated at the input face 10 of the component 1 reverberates within the layer stack due to reflections from the high shock impedance layer 32, thereby creating regions of constructive and destructive interference as the shock waves pass each other. When a shock enters the high shock impedance layer 132 from the low shock impedance layer 130, a portion of the shock is transmitted into the high shock impedance layer 132, while a portion is reflected back into the low shock impedance layer 130.

[0077] The portion in the low impact impedance layer 130 is accelerated as it now travels through the pre-impact material, the impact portion is then reflected from the boundary at the input end of the low impact impedance layer, and since it has been accelerated, the reflected portion eventually catches up with the portion of the impact that was originally transmitted into the high impact impedance layer 132. Through the arrangement of the low impact impedance layer 30 and the high impact impedance layer 32, the component 1 can be arranged so that multiple impact features are superimposed on the output face 12 of the component 1, thereby generating a transient high impact pressure state that can enter a target adjacent to the component output end 12.

[0078] The combination of the focused shape of the frustum-shaped cavity 5 and the parallel layers 30, 32 produces a component design that has been shown to greatly increase the impact pressure at the output end relative to the use of either feature alone. Impact reflections from the walls of the cavity 5 interact with axial impact reflections from the high impact impedance layer 32 to produce local thermodynamic high pressure areas. These high pressure areas expand in the component 1 and interact with additional impact reflections downstream to produce areas of higher impact pressure that are ultimately transmitted to the output end 11 of the cavity 5. Through the configuration of the parallel layer materials and thicknesses and the shape of the cavity 5, the pressure of the impact at the output end 11 and the uniformity of the impact state and shape can be controlled. It should be understood that although the thickness can vary between layers, each individual layer has a uniform thickness across its width.

[0079] In addition to creating conditions for localized impact superposition and constructive interference, the parallel layers 30, 32 also serve to effectively slow the impact transmission time through the component 1. This allows more energy from the projectile 13 to be collected and combined into a single impact state when ejected from the component 1.

[0080] Simulations and experiments have shown that for Figure 1 The component design of the embodiment of the invention can achieve a pressure multiplication factor of at least 15 for an input end radius / exit end radius ratio of about 9. For example, in the simulation, an output pressure of 1240 GPa was achieved with an input shock wave having a pressure of 83 GPa.

[0081] Figure 4 It shows that it can be used for example Figure 2 and Figure 3 A perspective cutaway view of a single first plate 31 in component 1 is shown. The first plate 31 is a flat disk defining a frustoconical subcavity 50 at its center. The subcavity 50 extends through the depth of the plate 31 so that the input end 509 and the output end 511 of the subcavity are open before stacking the first plates 31. The first plate 31 includes a plurality of holes 35, which are located near the circumferential edge of the first plate 31. The longitudinal axes of the holes 35 are parallel to the longitudinal axes of the subcavity 50 and perpendicular to the plane of the first plate 31. Each hole 35 is an alignment hole 35a configured to receive an alignment member (such as a pin), or a fastening hole 35b configured to receive a fastening member (such as a bolt).

[0082] Figure 5 It shows that it can be used for example Figure 2 and Figure 3 A perspective cutaway view of a single second plate 33 in the component 1 is shown. The second plate 33 is a solid flat disk. Figure 4Like the first plate 31 shown, the second plate 33 includes a plurality of holes 35 proximate a circumferential edge of the second plate 33. The longitudinal axes of the holes 35 are perpendicular to the plane of the second plate 33. The holes 35 in the first plate 31 and the second plate 33 are configured to be aligned so that fastening members (such as bolts) or alignment members (such as pins) can be inserted through the holes to align and secure the first plate 31 and the second plate 33 together.

[0083] Figure 6 An exploded view of a first plate 31 and a second plate 33 is shown, which are arranged in a stacked manner, for example to form Figure 2 and Figure 3 Part 1 shown. Figure 5 In the view of FIG. 5 , the subcavity 50 is unfilled. Figure 5 It is seen that the first plate 31 and the second plate 33 are stacked in an arrangement that alternates from one plate to the next between the first plate 31 and the second plate 33. Further, the first plate 31 and the second plate 33 are aligned so that the longitudinal axis of rotational symmetry of each plate is coaxial with the longitudinal axis of the other plate. Further, the alignment holes 35a are aligned to allow insertion of the alignment member 37. Figure 5 Only a single alignment member is shown in FIG. 3 , but it will be appreciated that an alignment member will be provided for each set of alignment holes 35a. The alignment member 37 maintains the alignment of the first plate 31 and the second plate 33 in the formed component.

[0084] Now refer to Figure 7 Detailed description of the method 100 for manufacturing the component 1 is provided in flowchart form. At step 101, a plurality of first plates 31 are formed. The first plates 31 may be formed in any known manner. For example, the first plates 31 may be cast. Alternatively, each first plate 31 may be cut from a larger sheet of material and milled to form the subcavities 50. The holes 35 may be formed in any known manner, such as by drilling.

[0085] At step 103, a plurality of second plates 33 are formed. The second plates 33 may be formed in any known manner. For example, the second plates 33 may be cast. Alternatively, each second plate 33 may be cut from a larger sheet of material. The holes 35 may be formed in any known manner, such as by drilling.

[0086] At step 105, one or more of the subcavities 50 are filled with a liquid cavity filling material 7. The cavity filling material 7 may be a curable liquid, such as a curable plastic or glue. One or more of the subcavities 50 are overfilled. Then at step 107, the liquid cavity filling material is cured. Depending on the cavity filling material 7, the cavity filling material 7 may be cured in any known manner. For example, the cavity filling material 7 may be cured using UV light or using heat. In embodiments where the cavity filling material 76 is an epoxy resin, the cavity filling material 7 is cured using UV light.

[0087] It should be understood that in embodiments, the subcavity 50 may be filled in other suitable ways. For example, the cavity filling material 7 may be applied using injection molding or additive manufacturing.

[0088] At step 109, the excess cavity filling material 7 and also the excess material of the first plate 31 itself are removed by milling. When the first plates 31 are formed, they are formed slightly thicker than the desired final dimensions so that the first plates 31 and the excess cavity filling material 7 can be removed by milling together. This helps to improve the quality of the surface finish. Since the cavity filling material 7 and the material of the plate itself are removed by milling together, there is no step at the edge of the sub-cavity 50.

[0089] At step 111, once all sub-cavities to be filled have been filled, the first plate 31 and the second plate 33 are placed as shown in FIG. Figure 6 The panels are arranged in parallel as shown, and are stacked so that the plurality of sub-cavities are at least partially aligned to form a combined component cavity 5. Alignment of the panels may be aided by inserting alignment members 37 into the alignment holes 35a.

[0090] Finally, at step 113, fastening members (bolts in the illustrated embodiment) are passed through the fastening holes 35b to secure the layers together. The fastening members ensure that the alignment between the first plate 31 and the second plate 33 is correct.

[0091] It should be understood that the description provided above is set forth in terms of manufacturing components 1 individually. It should be understood by those skilled in the art that for mass production, the first plate 31 and the second plate 33 for several components 1 may be manufactured at once. For example, a single sheet may be formed for each layer, the sheets corresponding to the first plate 31 having a plurality of milled sub-cavities 50. The sub-cavities 50 may be filled, the sheets milled, the sheets stacked and fastened together so that a complete element including a plurality of individual components 1 is formed. The components 1 themselves may then be cut out of the entire element, for example by laser cutting.

[0092] It should be understood that Figure 2 The components shown are purely exemplary and Figure 2Variants of the component 1 can also be produced using the production method according to the invention.

[0093] For example, it should be understood that not every sub-cavity 50 needs to be (eg, completely) filled with cavity filling material 7. For example, Figure 8 Shown as Figure 2 Component 301 of a variation of component 1 in which subcavity 350 forming input layer 333 is unfilled. First filling layer 335 in cavity 305 is a low impact impedance layer 330, as first filling layer 335 formed of high impact impedance layer 332 will result in a larger portion of the shock wave being reflected by first filling layer 335 and therefore not transmitted into the remainder of component 301. However, alternatives are contemplated, and first filling layer 335 formed of high impact impedance layer 332 may help to better couple the shock into component 301, as the impact impedance of the high impact impedance layer may be more similar to the impact impedance of the projectile 13 impacting the component.

[0094] exist Figure 8 In the embodiment of FIG. 3 , the impacting projectile 13 directly impacts only the body 303 of the component 301. This can result in the generation of axially converging shock reflections within the projectile 13, which are reflected into the cavity filling material 307 when the front face of the projectile 13 contacts the first filling layer 335. These transmitted-reflected shocks are then superimposed on the central axis within the cavity 305, thereby generating a high pressure state that expands toward the output end 311 as a Mach rod. The function of the cavity 305 and subsequent parallel layers 330, 332 is as described above with respect to Figure 2 described.

[0095] In the simulation, it meets Figure 8 The components of the embodiments have achieved a pressure multiplication factor of 5, where the pressure of the input shock wave is 140 GPa and the pressure of the output shock wave is 700 GPa.

[0096] Fig. 9 Shows Figure 2 Another variation of the embodiment wherein cavity 405 has a different shape. Fig. 9 The component 401 shown can also be manufactured using the manufacturing method according to the present invention. Figure 2 In the embodiment of FIG. 4 , the body 403 is formed of a plurality of layers, each layer defining a frustum-shaped sub-cavity 450 having an input end 4509 and an output end 4511. In the embodiment shown, each sub-cavity is a conical frustum, but other shapes are also contemplated. Fig. 9In the embodiment of the present invention, the cross-sectional area of ​​the input end 4509 of each sub-cavity 450 is larger than the cross-sectional area of ​​the output end 4511 of the previous sub-cavity. In the conical frustum embodiment, this means that the radius of the input end 4509 of each sub-cavity is larger than the radius of the output end 4511 of the previous sub-cavity.

[0097] Fig. 9 The component 401 shown is similar to the one described above. Figure 2 The substantially same manner of operation is described, but the overlapping output end 4511 and input end 4509 enable the impact transmitted from the cavity filling material 407 of the sub-cavity 450 to the body 403 of the component 401 to be partially recaptured by the input end 4509 of the latter sub-cavity 450 and focused back into the cavity filling material 407 contained in that sub-cavity. This can reduce the amount of impact loss, thereby producing a more efficient component 401. Further, because the sub-cavities 450 are discrete, different sub-cavities 450 can have different characteristics, such as input end diameter, output end diameter, thickness, material, and sub-cavity wall angle. It should be understood that although the thickness can vary between layers, each individual layer has a uniform thickness across its width.

[0098] In each of the above-described embodiments, the figures shown are vertical cross-sections of three-dimensional components, and thus they depict rotationally symmetrical embodiments. However, this is not essential to the invention.

[0099] It will be understood that the embodiments explicitly disclosed herein are intended to be exemplary, and that those skilled in the art will appreciate that features of the embodiments disclosed herein may be combined in combinations not explicitly mentioned to form new embodiments.

Claims

1. A method of manufacturing a component for manipulating an input shock wave, the method comprising: forming a plurality of plates, each plate defining a subcavity; at least partially filling one or more of the subcavities with one or more cavity-filling materials; as well as The plurality of sheets are stacked to form a component such that the subcavities are at least partially aligned and combine to define a layered component cavity containing the one or more cavity filling materials.

2. The method of claim 1, wherein: One or more of the plurality of plates are formed of a high density material.

3. The method according to claim 1 or 2, wherein: One or more of the plurality of plates are formed of metal.

4. A method as claimed in any preceding claim, wherein: The or each cavity filling material may have a density lower than a density of one or more of the plurality of plates.

5. A method as claimed in any preceding claim, wherein: Filling one or more of the subcavities with one or more cavity filling materials includes filling one or more subcavities with a castable material.

6. The method of claim 5, further comprising allowing the castable material to cure.

7. The method of claim 5 or 6, further comprising overfilling the one or more sub-cavities and milling away surfaces of one or more of the plurality of plates.

8. A method as claimed in any preceding claim, wherein: The component cavity comprises an input end for receiving the shock wave and an output end for outputting the shock wave, and wherein the shape of the component cavity is configured such that a cross-sectional area of ​​the input end is larger than a cross-sectional area of ​​the output end.

9. A method as claimed in any preceding claim, wherein: Each sub-cavity has an input end for receiving the shock wave and an output end for outputting the shock wave, and wherein one or more of the sub-cavities are shaped such that a cross-sectional area of ​​the input end is larger than a cross-sectional area of ​​the output end.

10. The method of claim 9, wherein: One or more of the sub-cavities are frustum-shaped.

11. The method of claim 10, wherein: One or more of the sub-cavities is a conical frustum.

12. A method as claimed in any preceding claim, wherein: Two or more of the plurality of plates include one or more holes configured to receive fastening members, and wherein the method includes securing the two or more plates together by placing one or more fastening members through the one or more holes.

13. A method as claimed in any preceding claim, wherein: Two or more of the plurality of plates include one or more alignment holes configured to receive alignment members, and wherein the method includes aligning the two or more plates together by placing one or more alignment members through the one or more alignment holes.

14. A method as claimed in any preceding claim, wherein: The plurality of plates is a plurality of first plates, and the method includes forming one or more second plates that do not include subcavities and stacking the second plates with the first plates.

15. The method of claim 14, wherein: The method includes stacking the plurality of first plates and the one or more second plates such that the plates alternate between first plates and second plates.

16. A method as claimed in any preceding claim, wherein: The thickness of the first plate gradually decreases from the component cavity input end to the component cavity output end.

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