公开(公告)号：US12049427B2

公开(公告)日：2024-07-30

申请号：US17682337

申请日：2022-02-28

Applicant: HRL Laboratories, LLC

Inventor： Zak C. Eckel ,  Tobias A. Schaedler ,  John H. Martin ,  Kenneth Cante

IPC: B33Y80/00 ,  B28B1/00 ,  B29C64/10 ,  B29C64/379 ,  B33Y40/10 ,  B33Y40/20 ,  B33Y70/10 ,  C04B35/117 ,  C04B35/14 ,  C04B35/44 ,  C04B35/46 ,  C04B35/488 ,  C04B35/515 ,  C04B35/532 ,  C04B35/56 ,  C04B35/563 ,  C04B35/565 ,  C04B35/571 ,  C04B35/58 ,  C04B35/581 ,  C04B35/589 ,  C04B35/597 ,  C04B35/622 ,  C04B35/628 ,  C04B35/634 ,  C04B35/64 ,  C04B35/80 ,  C08L83/08 ,  C09D5/33 ,  C09D7/40 ,  C09D7/61 ,  C09D7/62 ,  C09D11/03 ,  C09D11/037 ,  C09D11/101 ,  C09D11/102 ,  B29C35/08 ,  B29C64/129 ,  B29C71/02 ,  B29K83/00 ,  B29K105/00 ,  B29K509/04 ,  B33Y10/00 ,  C08G77/18 ,  C08G77/20 ,  C08G77/28 ,  C08K3/34 ,  C08K7/00 ,  C08K7/10 ,  C08K9/04

CPC classification number: C04B35/5603 ,  B28B1/001 ,  B29C64/10 ,  B29C64/379 ,  B33Y40/10 ,  B33Y40/20 ,  B33Y70/10 ,  B33Y80/00 ,  C04B35/117 ,  C04B35/14 ,  C04B35/44 ,  C04B35/46 ,  C04B35/488 ,  C04B35/515 ,  C04B35/532 ,  C04B35/5611 ,  C04B35/5622 ,  C04B35/563 ,  C04B35/565 ,  C04B35/571 ,  C04B35/58 ,  C04B35/58014 ,  C04B35/58028 ,  C04B35/581 ,  C04B35/589 ,  C04B35/597 ,  C04B35/62218 ,  C04B35/62836 ,  C04B35/62839 ,  C04B35/63448 ,  C04B35/64 ,  C04B35/80 ,  C08L83/08 ,  C09D5/004 ,  C09D7/61 ,  C09D7/62 ,  C09D7/67 ,  C09D7/68 ,  C09D7/69 ,  C09D7/70 ,  C09D11/03 ,  C09D11/037 ,  C09D11/101 ,  C09D11/102 ,  B29C2035/0827 ,  B29C2035/0838 ,  B29C64/129 ,  B29C71/02 ,  B29K2083/00 ,  B29K2105/0002 ,  B29K2509/04 ,  B29K2995/0026 ,  B29K2995/003 ,  B33Y10/00 ,  C04B2235/3826 ,  C04B2235/3895 ,  C04B2235/483 ,  C04B2235/5216 ,  C04B2235/5436 ,  C04B2235/6026 ,  C04B2235/6562 ,  C04B2235/6565 ,  C04B2235/77 ,  C04B2235/96 ,  C08G77/18 ,  C08G77/20 ,  C08G77/28 ,  C08K3/34 ,  C08K7/00 ,  C08K7/10 ,  C08K9/04 ,  C08K2201/005 ,  C08L83/08 ,  C08L83/00

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.

公开(公告)号：US11806956B1

公开(公告)日：2023-11-07

申请号：US17372186

申请日：2021-07-09

Applicant: HRL LABORATORIES, LLC

Inventor： Jacob M. Hundley ,  Eric C. Clough ,  Zak C. Eckel ,  David Page ,  Sophia S. Yang

IPC: B29C73/10 ,  B64F5/40 ,  B29C73/02 ,  B29C73/06 ,  B23P6/00 ,  B32B3/12 ,  B29L7/00 ,  B64C1/00

CPC classification number: B29C73/10 ,  B23P6/00 ,  B29C73/02 ,  B29C73/06 ,  B64F5/40 ,  B29L2007/002 ,  B32B3/12 ,  B32B2605/18 ,  B64C2001/0072 ,  F05D2230/80

Abstract: A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.

公开(公告)号：US11148375B1

公开(公告)日：2021-10-19

申请号：US16654840

申请日：2019-10-16

Applicant: HRL LABORATORIES, LLC

Inventor： Jacob M. Hundley ,  Eric C. Clough ,  Zak C. Eckel ,  David Page ,  Sophia S. Yang

IPC: B29C73/02 ,  B29C73/10 ,  B64F5/40 ,  B32B3/12 ,  B64C1/00 ,  B29L7/00

Abstract: A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.

公开(公告)号：US10946600B1

公开(公告)日：2021-03-16

申请号：US15690229

申请日：2017-08-29

Applicant: HRL Laboratories, LLC

Inventor： Jacob M. Hundley ,  Eric C. Clough ,  Zak C. Eckel ,  David Page ,  Sophia S. Yang

IPC: B29C73/02 ,  B29C73/10 ,  B29C73/24 ,  B29K105/04 ,  B29L31/60

Abstract: A method for repairing a composite structure. A damaged portion of a first facesheet of the structure is removed, forming a hole in the first facesheet. A damaged portion of the underlying core is removed to form a cavity in the sandwich. If the second facesheet is damaged, the damaged section is removed, and covered and sealed with a facesheet repair section. If the core material is an open-cell material, a dam is formed around the perimeter of the cavity, to act as a barrier between the cavity and the core material. The cavity is at least partially filled with a photomonomer resin, which then is illuminated through a mask with collimated light to form a truss structure in the cavity. Residual photomonomer resin is removed, and a facesheet repair section is bonded over the hole in the first facesheet.

公开(公告)号：US10882220B1

公开(公告)日：2021-01-05

申请号：US16256735

申请日：2019-01-24

Applicant: HRL LABORATORIES, LLC

Inventor： Jie Ensberg ,  Christopher J. Ro ,  Sophia S. Yang ,  Zak C. Eckel ,  Eric C. Clough

IPC: B29C35/08 ,  B29C33/40 ,  B29C33/38 ,  B32B1/02 ,  B32B3/12 ,  B29C33/60 ,  B29L31/00 ,  B29K105/00

Abstract: A method and/or system for forming a micro-truss structure in an essentially arbitrary shape. A mold that has a transparent portion, and having an interior volume in the desired shape, is filled with photomonomer resin. The material for the transparent portion of the mold is selected to be a material that is index-matched to the photomonomer resin. The filled mold, placed into a bath of transparent fluid index-matched to the transparent portion of the mold, and illuminated, from outside the fluid, through a photomask, with collimated light. The collimated light travels through the photomask forming beams of light that enter the transparent fluid, propagate into the mold, and form a micro-truss structure in the shape of the interior volume of the mold. The micro-truss structure may then be removed from the mold, or part or all of the mold may be left adhered to the micro-truss structure, forming covering face sheets.

公开(公告)号：US10822460B1

公开(公告)日：2020-11-03

申请号：US16029527

申请日：2018-07-06

Applicant: HRL Laboratories, LLC

Inventor： Phuong Bui ,  Zak C. Eckel ,  April R. Rodriguez

IPC: C08G77/62 ,  C04B35/589 ,  C04B35/597 ,  B28B1/00 ,  B33Y70/00 ,  C04B35/571 ,  B33Y10/00

Abstract: Some variations provide a preceramic resin precursor formulation comprising: first molecules containing at least one Si—N bond and/or at least one Si—C bond; and second molecules of the formula R4—N═C═S, wherein R4 may be a UV-active functional group. In some embodiments, R4 is selected from ethynyl, vinyl, allyl, acrylate, methacrylate, vinyl ether, epoxide, oxetane, thiol, thioketone, isothiocyanate, or combinations thereof. The first and second molecules are reacted with an isothiocyanate to form third molecules, providing a preceramic radiation-curable resin composition. The resin composition contains at least one Si—N bond and/or at least one Si—C bond in the main chain of the third molecules. Side chains of the third molecules may be selected from hydrogen, unsubstituted or substituted hydrocarbon groups, halides, esters, amines, hydroxyl, or cyano. The resin composition may be 3D printed and thermally treated to generate a ceramic material.

公开(公告)号：US10745525B2

公开(公告)日：2020-08-18

申请号：US16190313

申请日：2018-11-14

Applicant: HRL Laboratories, LLC

Inventor： Zak C. Eckel

IPC: C08F2/46 ,  C08F2/50 ,  C08G61/04 ,  C08G77/50 ,  C04B35/56 ,  C04B35/571 ,  C04B35/58 ,  C04B35/583 ,  C04B35/589 ,  C04B35/597 ,  C04B35/622 ,  C04B35/632 ,  G03F7/004 ,  G03F7/025 ,  G03F7/027 ,  G03F7/029 ,  G03F7/031 ,  G03F7/038 ,  G03F7/075 ,  B33Y10/00 ,  B28B1/00 ,  C04B35/515 ,  C04B35/64 ,  C08J3/28 ,  G03F7/00 ,  B33Y70/00 ,  B33Y80/00

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.

公开(公告)号：US10703025B1

公开(公告)日：2020-07-07

申请号：US15840146

申请日：2017-12-13

Applicant: HRL Laboratories, LLC

Inventor： Scott M. Biesboer ,  Tobias A. Schaedler ,  Jacob M. Hundley ,  Zak C. Eckel

IPC: B29C39/00 ,  C04B35/56 ,  B29C64/106 ,  B29C39/38 ,  B29C64/30 ,  B29C65/56 ,  B29C65/02 ,  B28B1/00 ,  B28B1/14 ,  B33Y10/00 ,  B33Y70/00 ,  C04B35/64 ,  B29L31/00 ,  B29K83/00 ,  B29K85/00 ,  B29K105/16

Abstract: Some variations provide a process for fabricating a ceramic structure, the process comprising: producing a plurality of preceramic polymer parts; chemically, physically, and/or thermally joining the preceramic polymer parts together, to generate a preceramic polymer structure; thermally treating the preceramic polymer structure, to generate a ceramic structure; and recovering the ceramic structure. The process may employ additive manufacturing, subtractive manufacturing, casting, or a combination thereof. A composite overwrap may be applied to the preceramic polymer structure prior to pyrolysis, and the composite overwrap also pyrolyzes to a ceramic composite and is a part of the final ceramic structure. The ceramic structure may be silicon oxycarbide, silicon carbide, silicon nitride, silicon oxynitride, silicon carbonitride, silicon boronitride, silicon boron carbonitride, or boron nitride, for example. The ceramic structure may have at least one dimension of 1 meter or greater, and may be a fully integrated ceramic object with no seams.

公开(公告)号：US10600739B1

公开(公告)日：2020-03-24

申请号：US16059943

申请日：2018-08-09

Applicant: HRL LABORATORIES, LLC

Inventor： Florian G. Herrault ,  Zak C. Eckel ,  Tobias A. Schaedler ,  Robert Mone

IPC: H01L23/538 ,  H01L21/48 ,  H01L23/15 ,  H01L23/50 ,  H01L23/498 ,  H01L23/00 ,  B29C64/10 ,  H05K1/03

Abstract: An interposer includes an interposer substrate having a series of vias, and a series of metallic interconnects in the series of vias. The interposer substrate has a first surface and a second surface opposite the first surface. The interposer substrate includes a dielectric material. A first pitch of the series of vias at a first end of the series of vias is different than a second pitch of the series of vias at a second end of the series of vias.

公开(公告)号：US10061078B1

公开(公告)日：2018-08-28

申请号：US14583298

申请日：2014-12-26

Applicant: HRL Laboratories, LLC

Inventor： Zak C. Eckel ,  Jacob M. Hundley ,  Alan J. Jacobsen ,  Eric C. Clough ,  Thomas Boundy

IPC: B32B3/10 ,  G02B6/12 ,  B32B27/08 ,  B32B27/36 ,  G02B6/138

CPC classification number: G02B6/12002 ,  B32B3/10 ,  B32B27/08 ,  B32B27/365 ,  B32B2250/03 ,  B32B2255/26 ,  B32B2551/00 ,  G02B6/138

Abstract: In some variations, a polymer-based microlattice structure includes a plurality of intersecting micro-truss structural elements each comprising a thermoset first polymer, and a continuous coating layer (with a second polymer) that substantially encapsulates each of the micro-truss structural elements, wherein the second polymer in the continuous coating layer bonds the thermoset first polymer to a substrate. The micro-truss structural elements preferably are architecturally ordered and the coating layer is uniformly distributed within the microlattice structure. The polymer coating layer may be present over the entire microlattice surface area, thereby increasing bond area to improve toughness. The microlattice structure may also have higher glass-transition temperature and chemical resistance, compared to a microlattice structure without the coating layer. Methods of forming a polymer-based microlattice structure are also disclosed.