Ordered Cellular Structures via Volumetric Photopolymerization
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Solution Overview
Problem
Current methods for manufacturing cellular polymer and ceramic structures are limited in creating thicker, ordered structures with controlled cell size and spacing, and often require lengthy processing times and high-temperature molds, while also resulting in random cell distributions and bulk porosity.
Innovation Solution
The method involves irradiating a volume of photo-monomer with light beams through a series of apertures in a photomask to form ordered cellular structures, which can be post-cured and pyrolyzed to create ceramic structures with controlled unit cell shapes and sizes, allowing for spatial tailoring of mechanical properties and non-planar shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography is used to manufacture cellular structures, then manufacturing precision is improved, but the structures are limited to thin dimensions only
Solution Approach 1:
The patent transitions from traditional 2D photolithography to 3D volumetric photopolymerization. By using a digital micromirror device (DMD) to project patterns through the entire depth of the photo-monomer layer simultaneously, the method achieves precise control of cell structures in three dimensions, enabling thick structures with uniform cell morphology throughout the volume.
2Length of moving object
If 3D-printing techniques are used to manufacture thicker structures, then structure thickness is improved, but productivity decreases due to long print times
Solution Approach 1:
The patent employs periodic pulsed illumination through a DMD device, where individual micromirrors are switched on and off in sequential patterns to build up the 3D structure layer by layer. This periodic action enables controlled volumetric polymerization that is both fast and precise, achieving thick structures without the lengthy print times of conventional 3D printing.
3Ease of manufacture
If related art methods are used to manufacture ceramic foams, then ceramic structures are produced, but manufacturing precision deteriorates due to random cell distribution
Solution Approach 1:
The patent performs preliminary patterning of the photo-monomer into an ordered cellular structure with precise cell size, shape, and spacing before ceramic conversion. The photomask with pre-designed aperture patterns guides the light to create uniform cellular architectures in the polymer precursor, which are then replicated in the final ceramic structure through pyrolysis, ensuring uniform cell distribution throughout.
4Stability of the object's composition
If high temperature molds are used during ceramic firing, then ceramic shape is maintained, but device complexity increases
Solution Approach 1:
The patent changes the material state parameter by using photopolymerizable preceramic polymers that can be cured at low temperatures to form dimensionally stable green bodies. These pre-cured structures maintain their shape during subsequent high-temperature ceramic firing without requiring complex high-temperature molds, as the polymer framework provides structural integrity before densification.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of thicker, ordered cellular structures with precise control over cell size and spacing, achieving uniform porosity and tailored mechanical properties, suitable for applications in aerospace and automotive industries.
Implementation Method 1
irradiating a volume of photo-monomer with light beams through a series of apertures in a photomask to form ordered cellular structures
Implementation Method 2
pyrolyzing the fully cured polymer cellular structure to form the ceramic cellular structure
Data Source
AI summary
A method of manufacturing an ordered cellular structure including a series of interconnected unit cells. Each unit cell includes at least one straight wall segment. The method includes irradiating a volume of photo-monomer in a reservoir with at least one light beam from at least one light source to form the ordered cellular structure. Irradiating the volume of photo-monomer includes directing the at least one light beam though a series of interconnected apertures defined in a photo-mask covering the reservoir.