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公开(公告)号：US20190160734A1
公开(公告)日：2019-05-30
申请号：US15823336
申请日：2017-11-27
Applicant: HRL Laboratories, LLC
Inventor： Scott M. Biesboer , Jacob M. Hundley , Zak C. Eckel
IPC: B29C64/135 , B29C64/245 , G03F7/20 , G03F7/038 , C08L1/02 , C08L23/06 , C08L23/12 , C08L33/08 , C08L55/02 , C08L67/04 , B33Y30/00 , B33Y10/00
Abstract: A sacrificial substrate for use in stereolithography, having a first surface configured to be attached to a build platform, and a second surface of the sacrificial substrate configured to be attached to a photopolymer part. The sacrificial substrate physically separates the build platform and the photopolymer part, and serves as the deposition surface for the photopolymer part in place of the build platform. The sacrificial substrate may be separated from the build platform and then separated from the photopolymer part via pyrolysis, oxidation, or etching to thereby yield the free photopolymer part without subjecting the part to excess physical force or damage.
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公开(公告)号：US10197708B2
公开(公告)日：2019-02-05
申请号：US14462306
申请日：2014-08-18
Applicant: HRL Laboratories, LLC
Inventor： Jacob M. Hundley , Zak C. Eckel , Sophia S. Yang , Alan J. Jacobsen , William Carter
Abstract: Methods of manufacturing a structure having at least one plated region and at least one unplated region. The method includes plating a metal on a polymer structure having a first region accepting the metal and a second region unreceptive to the metal plating. The first region may include fully-cured polymer optical waveguides and the second region may include partially-cured polymer optical waveguides. The first region may include a first polymer composition and the second region may include a second polymer composition different than the first polymer composition.
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公开(公告)号：US20180341184A1
公开(公告)日：2018-11-29
申请号：US15606861
申请日：2017-05-26
Applicant: HRL LABORATORIES, LLC
Inventor： Jacob M. Hundley , Zak C. Eckel , Emily C. Schueller , Scott M. Biesboer
Abstract: An aperture system for a bottom-up stereolithography device including a reservoir having a lower opening, an aperture including a flexible membrane positioned within the reservoir and covering the lower opening, and a boundary seal positioned around a periphery of the flexible membrane, the boundary seal including one or more boundary seal components and immobilizing the periphery of the flexible membrane against the reservoir. The flexible membrane is formed of a material having a low affinity for a liquid resin used in the stereolithography device as well as cured photopolymer resin parts produced by the device. In addition, the flexible membrane is able to deform as the cured resin part is pulled away from the aperture, thus enabling lower energy mixed mode adhesive failure to occur at the interface between the cured resin and the aperture and reducing the chance of cohesive damage to the cured photopolymer part.
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公开(公告)号：US20160047980A1
公开(公告)日：2016-02-18
申请号：US14461841
申请日：2014-08-18
Applicant: HRL LABORATORIES, LLC
Inventor： David Page , Sophia S. Yang , Alan J. Jacobsen , Zak C. Eckel , Christopher S. Roper , William Carter
CPC classification number: G02B6/1225 , B29C64/129 , B29C64/286 , B29K2096/00 , B33Y10/00 , B33Y30/00 , B33Y80/00 , G02B1/002 , G02B6/138 , G02B2006/12173 , G03F7/0037 , G03F7/2012 , G03F7/70416
Abstract: A system and method for forming microlattice structures of large thickness. In one embodiment, a photomonomer resin is secured in a mold having a transparent bottom, the interior surface of which is coated with a mold-release agent. A substrate is placed in contact with the top surface of the photomonomer resin. The photomonomer resin is illuminated from below by one or more sources of collimated light, through a photomask, causing polymer waveguides to form, extending up to the substrate, forming a microlattice structure connected with the substrate. After a layer of microlattice structure has formed, the substrate is raised using a translation-rotation system, additional photomonomer resin is added to the mold, and the photomonomer resin is again illuminated through the photomask, to form an additional layer of microlattice structure. The process is repeated multiple times to form a stacked microlattice structure.
Abstract translation: 一种用于形成大厚度的微晶格结构的系统和方法。 在一个实施方案中，将光单体树脂固定在具有透明底部的模具中，其内表面涂覆有脱模剂。 将基底放置成与光单体树脂的顶表面接触。 通过一个或多个准直光源通过光掩模从下面照射光单体树脂，导致聚合物波导形成，延伸到衬底，形成与衬底连接的微晶格结构。 在形成一层微晶格结构之后，使用平移 - 旋转系统升高基板，向模具中加入额外的光单体树脂，并且通过光掩模再次照射光单体树脂，以形成附加的微格子结构层。 该过程重复多次以形成堆叠的微格子结构。
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公开(公告)号：US11299430B2
公开(公告)日：2022-04-12
申请号：US15822203
申请日：2017-11-26
Applicant: HRL Laboratories, LLC
Inventor： Zak C. Eckel , Tobias A. Schaedler , John H. Martin , Kenneth Cante
IPC: C04B35/56 , C09D11/037 , B29C64/379 , B33Y40/00 , C04B35/58 , C04B35/589 , C08L83/08 , C04B35/571 , C04B35/597 , C04B35/515 , C04B35/117 , C04B35/14 , C04B35/44 , C04B35/46 , C04B35/488 , C04B35/532 , C04B35/563 , C04B35/565 , C04B35/581 , C04B35/80 , B33Y70/00 , C04B35/622 , C04B35/628 , C04B35/634 , C04B35/64 , B29C64/10 , C09D7/61 , B28B1/00 , C09D11/03 , C09D11/101 , C09D11/102 , B33Y80/00 , C09D7/40 , C09D7/62 , C09D5/33 , B29C35/08 , B29C64/129 , B29C71/02 , C08G77/18 , C08G77/20 , C08G77/28 , B29K105/00 , C08K3/34 , B33Y10/00 , B29K83/00 , B29K509/04 , C08K7/00 , C08K7/10 , C08K9/04
Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.
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Patent Agency Ranking
公开(公告)号：US11141878B1
公开(公告)日：2021-10-12
申请号：US16218047
申请日：2018-12-12
Applicant: HRL Laboratories, LLC
Inventor： Tobias A. Schaedler , Zak C. Eckel
IPC: C04B35/565 , C04B35/571 , B22C9/00 , B28B1/00 , C04B35/56 , C04B35/626 , B22C9/04 , B22C7/02 , B33Y10/00 , B33Y70/00 , B33Y80/00
Abstract: A method and a fugitive mold for producing a cast-metal part are provided. In some embodiments, the fugitive mold may be formed by three-dimensionally (3D) printing a preceramic resin in the shape of a fugitive mold; curing the preceramic resin to form a preceramic polymer, and pyrolyzing the fugitive mold to convert the preceramic polymer to a metastable ceramic material. The metastable ceramic material may include an amorphous silicon oxycarbide ceramic. A cast-metal part may be formed by filling the fugitive mold with a liquid metal or alloy, and allowing the liquid metal or alloy to solidify over a first length of time. The cast-metal part may then be retrieved by heating the fugitive mold at a temperature lower than the melting point of the cast-metal part for a second length of time longer than the first length of time to disintegrate the metastable ceramic material.
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公开(公告)号：US10894748B1
公开(公告)日：2021-01-19
申请号：US16510573
申请日：2019-07-12
Applicant: HRL LABORATORIES, LLC
Inventor： Zak C. Eckel , Tobias A. Schaedler , Eric C. Clough
Abstract: 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.
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48.发明申请公开(公告)号：US20200341171A1
公开(公告)日：2020-10-29
申请号：US16926478
申请日：2020-07-10
Applicant: HRL LABORATORIES, LLC
Inventor： Jacob M. Hundley , Zak C. Eckel , Sophia S. Yang , Alan J. Jacobsen , William Carter
Abstract: Methods of manufacturing a structure having at least one plated region and at least one unplated region. The method includes plating a metal on a polymer structure having a first region accepting the metal and a second region unreceptive to the metal plating. The first region may include fully-cured polymer optical waveguides and the second region may include partially-cured polymer optical waveguides. The first region may include a first polymer composition and the second region may include a second polymer composition different than the first polymer composition.
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公开(公告)号：US10737984B2
公开(公告)日：2020-08-11
申请号：US15822197
申请日：2017-11-26
Applicant: HRL Laboratories, LLC
Inventor： Tobias A. Schaedler , Zak C. Eckel , Scott Biesboer , Kenneth Cante
IPC: C04B35/56 , C09D11/037 , C04B35/58 , C04B35/589 , C08L83/08 , C04B35/571 , C04B35/597 , B33Y70/00 , C04B35/622 , C04B35/628 , C04B35/634 , C04B35/64 , C04B35/80 , B29C64/10 , C09D7/61 , B28B1/00 , C09D11/03 , C09D11/101 , C09D11/102 , B33Y40/00 , B33Y80/00 , B29C64/379 , C09D7/40 , C09D7/62 , C09D5/33 , B29C35/08 , B29C64/129 , B29C71/02 , C08G77/18 , C08G77/20 , C08G77/28 , B29K105/00 , C08K3/34 , B33Y10/00 , B29K83/00 , B29K509/04 , C08K7/00 , C08K7/10 , C08K9/04
Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.
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公开(公告)号：US20200216617A1
公开(公告)日：2020-07-09
申请号：US16824157
申请日：2020-03-19
Applicant: HRL Laboratories, LLC
Inventor： Zak C. Eckel
IPC: C08G77/50 , G03F7/00 , C08J3/28 , C04B35/64 , C04B35/622 , C04B35/515 , B28B1/00 , B33Y10/00 , G03F7/075 , G03F7/038 , G03F7/031 , G03F7/029 , G03F7/027 , G03F7/025 , G03F7/004 , C04B35/632 , C04B35/597 , C04B35/589 , C04B35/583 , C04B35/58 , C04B35/571 , C04B35/56
Abstract: This disclosure enables direct 3D printing of preceramic polymers, which can be converted to fully dense ceramics. Some variations provide a preceramic resin formulation comprising a molecule with two or more C═X double bonds or C≡X triple bonds, wherein X is selected from C, S, N, or O, and wherein the molecule further comprises at least one non-carbon atom selected from Si, B, Al, Ti, Zn, P, Ge, S, N, or O; a photoinitiator; a free-radical inhibitor; and a 3D-printing resolution agent. The disclosed preceramic resin formulations can be 3D-printed using stereolithography into objects with complex shape. The polymeric objects may be directly converted to fully dense ceramics with properties that approach the theoretical maximum strength of the base materials. Low-cost structures are obtained that are lightweight, strong, and stiff, but stable in the presence of a high-temperature oxidizing environment.
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