Fabrication and design of composites with architected layers
In an aspect, a composite material system comprises: a structure having an architected three-dimensional geometry; wherein said three-dimensional geometry is monolithic and deterministic; and a matrix phase; wherein said matrix phase at least partially infiltrates said structure. In some embodiments, the three-dimensional geometry is a nano- or micro-architected three-dimensional geometry.
1 . A composite material system comprising:
a porous structure having an architected three-dimensional geometry;
wherein said three-dimensional geometry is monolithic and deterministic; and wherein the three-dimensional geometry is a non-stochastic geometry;
wherein said structure comprises glassy carbon, graphitic carbon, amorphous carbon, pyrolytic carbon, graphite, carbon black, or any combination thereof; and
a matrix phase comprising a polymer, an epoxy, a carbon allotrope, a ceramic, a metal, a viscous fluid, or any combination thereof;
wherein said matrix phase infiltrates said structure by at least 20% by volume.
2 . The composite material system of claim 1 , wherein the three-dimensional geometry is a nano- or micro-architected three-dimensional geometry.
3 . The composite material system of claim 1 , wherein the structure is characterized by an area-normalized impact energy mitigation metric (ψ) selected from the range of 2×10 4 J/m 2 to 4×10 5 J/m 2 ; or wherein the structure is characterized by a density-normalized impact energy mitigation metric (ψ) selected from the range of 1.9×10 6 J/kg to 4×10 6 J/kg.
4 . The composite material system of claim 1 , wherein said structure is characterized by a restitution coefficient that is selected from the range of 0.8 to 0.3.
5 . The composite material system of claim 1 , wherein said structure is characterized by at least one vibrational frequency band gap.
6 . The composite material system of claim 5 , wherein said at least one vibrational frequency band gap is deterministic.
7 . The composite material system of claim 5 , wherein said at least one vibrational frequency band gap is within the range of 0.1 MHz to 200 MHz.
8 . The composite material system of claim 1 being characterized by a damping ratio of at least 1.2.
9 . The composite material system of claim 1 , wherein said three-dimensional geometry comprises at least one surface feature.
10 . The composite material system of claim 9 , wherein: at least a portion of said at least one surface feature is characterized by a non-zero Gaussian curvature, at least a portion of said at least one surface feature is characterized by a non-zero mean curvature, at least a portion of said at least one surface feature is characterized by a zero mean curvature, said at least one surface feature is characterized by a non-uniform Gaussian curvature or a non-uniform mean curvature, said at least one surface feature is characterized by a uniform Gaussian curvature or a uniform mean curvature, a thickness dimension of said at least one surface feature is non-uniform throughout said at least one surface feature, or a thickness dimension of said at least one surface feature is uniform throughout said at least one surface feature.
11 . The composite material system of claim 1 , wherein the three-dimensional geometry is characterized as a spinodal geometry.
12 . The composite material system of claim 1 , wherein the structure is characterized by a slope of normalized effective elastic modulus versus relative density that is selected from the range of 1 to 1.3.
13 . The composite material system of claim 1 , wherein the three-dimensional geometry comprises a resonator.
14 . The composite material system of claim 13 , wherein the resonator comprises a micro-inertia feature.
15 . The composite material system of claim 13 , wherein the resonator comprises a cantilever beam feature and a micro-inertia feature connected to an end of said cantilever beam feature.
16 . The composite material system of claim 1 , wherein the three-dimensional geometry is characterized by a unit cell geometry, said unit cell geometry comprising a resonator.
17 . The composite material system of claim 1 , wherein said structure is characterized by deterministic anisotropic damping characterized by damping at least 1% greater along a first direction than along a second direction.
18 . The composite material system of claim 1 , wherein said structure exhibits vibrational Bragg scattering and wherein said structure does not exhibit vibrational local resonance.
19 . The composite material system of claim 1 , wherein said structure comprises a carbon allotrope material, a polymer, a ceramic material, a metal material, or any combination thereof.
20 . The composite material system of claim 1 , wherein said three-dimensional geometry is a node-free geometry.
21 . The composite material system of claim 1 , wherein the structure comprises at least one hollow feature.
22 . The composite material system of claim 1 , wherein said three-dimensional geometry comprises at least one longitudinal feature, and wherein: at least a portion of said at least one longitudinal feature is characterized by a non-zero curvature along a longitudinal direction of said feature, said at least one longitudinal feature is characterized by a non-uniform curvature along a longitudinal direction of said feature, or said at least one longitudinal feature has at least one cross-sectional dimension that is non-uniform along a longitudinal direction of said feature.
23 . The composite material system of claim 1 , wherein said three-dimensional geometry comprises at least one feature having a cross-sectional shape that is non-uniform.
24 . The composite material system of claim 1 , wherein said structure defines a three-dimensional external boundary shape; and wherein said three-dimensional geometry comprises at least one feature that intersects said boundary shape at only one or zero points of intersection.
25 . The composite material system of claim 1 , wherein a three-dimensional external boundary shape defined by said structure corresponds to a shape of the composite material system.
26 . The composite material system of claim 1 , wherein a three-dimensional external boundary shape defined by said structure is hollow.
27 . The composite material system of claim 1 , wherein said three-dimensional geometry is an overall three-dimensional geometry comprising at least a primary three-dimensional geometry and a secondary three-dimensional geometry, wherein said primary and said secondary three-dimensional geometries are different.
28 . The composite material system of claim 1 , wherein said structure comprises a closed region that is free of said matrix phase.
29 . The composite material system of claim 1 , wherein said structure is enclosed within said matrix phase such that no portion of said structure exists beyond external boundaries of said matrix phase.
30 . The composite material system of claim 1 , wherein at least a portion of said three-dimensional geometry is characterized as a tetrakaidecahedron, Weaire-Phelan geometry, honeycomb geometry, auxetic geometry, an octet-truss geometry, an octahedron, a diamond lattice, a 3D kagome geometry, a tetragonal geometry, a cubic geometry, a tetrahedron, a space-filling polyhedron, a periodic minimal surface, a triply periodic minimal surface geometry, a spinodal geometry, a chiral geometry, or a combination of these.
31 . The composite material system of claim 1 , wherein the structure is characterized by one or more features having at least one physical size dimension, wherein said features comprise one or more of struts, beams, ties, trusses, sheets, surfaces, spheres, ellipses, and shells.
32 . The composite material system of claim 1 , wherein said structure is characterized by a relative density selected from the range of 5% to 99.9%.
33 . The composite material system of claim 1 , wherein said structure is characterized by an elasticity, said elasticity of said structure being deterministic.
34 . The composite material system of claim 1 , wherein said structure is characterized as having a bending-dominated mode or a stretching-dominated mode.
35 . The composite material system of claim 1 , wherein said structure comprises a coating.
36 . The composite material system of claim 1 , wherein the three-dimensional geometry comprises a unit cell geometry.
37 . The composite material system of claim 1 , wherein the three-dimensional geometry is characterized by at least one unit cell geometry, the unit cell having at least one overall physical dimension selected from the range of 10 nm to 20 μm.
38 . The composite material system of claim 1 , wherein the three-dimensional geometry is characterized by at least one unit cell geometry, the unit cell having at least one overall physical dimension selected from the range of 1 μm to 200 μm.
39 . The composite material system of claim 1 , wherein the structure is at least 1% by-mass infiltrated by the matrix phase.
40 . The composite material system of claim 1 , wherein said structure is not a foam.
41 . The composite material system of claim 1 , wherein said three-dimensional geometry is both unitary interconnected and continuous.
42 . The composite material system of claim 1 , wherein every portion or feature of the three-dimensional geometry is directly or indirectly bonded to, fused with, or otherwise belongs to the same uninterrupted phase with respect to another portion or another feature, respectively, of the three-dimensional geometry.
43 . The composite material system of claim 1 , wherein the structure comprises a pyrolytic carbon.
44 . The composite material system of claim 1 , wherein at least a portion of said three-dimensional geometry is characterized by a beam- or shell-based geometry; wherein said beam- or shell-based geometry is not symmetric, is not periodic, or is not regularly tessellated.
45 . The composite material system of claim 1 , wherein said three-dimensional geometry is not symmetric.
46 . The composite material system of claim 1 , wherein said three-dimensional geometry is a spinodal geometry and is not symmetric.
47 . The composite material system of claim 1 , wherein said three-dimensional geometry is not periodic.
48 . The composite material of claim 1 , wherein the structure comprises at least 50% by volume of the glassy carbon, graphitic carbon, amorphous carbon, pyrolytic carbon, graphite, carbon black, or any combination thereof.
49 . A method of making a composite material system, said method comprising steps of:
preparing a structure via an additive manufacturing process; wherein:
said structure has an architected three-dimensional geometry; and
said three-dimensional geometry is monolithic and deterministic; and wherein the three-dimensional geometry is a non-stochastic geometry;
wherein said structure comprises glassy carbon, graphitic carbon, amorphous carbon, pyrolytic carbon, graphite, carbon black, or any combination thereof;
infiltrating said structure with a matrix phase such that said structure is infiltrated by said matrix phase by at least 20% by volume; wherein the matrix phase comprises a polymer, an epoxy, a carbon allotrope, a ceramic, a metal, a viscous fluid, or any combination thereof;
thereby making said composite material system.