Abstract: The armor system according to the present invention also exploits synergistic multi-layering to provide different properties as a function of depth within a sandwich panel. Various embodiments of the invention include a combination of composite sandwich topology concepts with hard, strong materials to provide structures that (i) efficiently support static and fatigue loads, (ii) mitigate the blast pressure transmitted to a system that they protect, (iii) provides very effective resistance to projectile penetration, and (iv) minimizes shock (stress wave) propagation within the multi-layered armor sandwich structure. By using small pieces of highly constrained ceramic, the concept has significant multi-hit potential.

Abstract: An embodiment provides a protection structure comprising: open cell core structure; a top face sheet coupled to said core structure; a bottom face sheet coupled to said core structure distal from said top face sheet; a projectile arresting layer coupled to said top face sheet distal from said core structure; and a fragment catching layer couple to said bottom face sheet distal from said core.

Abstract: Methods and apparatuses for passive jet blast deflection or the like. Use of the passive jet blast deflector permits the efficient dispersal of a fast moving local heat source into the environment through passive means while providing a high strength structure. The jet blast deflector system may include a first plate, a second plate, and a cellular core disposed between them adapted to allow cooling ambient air to flow through the cellular core, wherein the first plate, second plate, and core are all seamlessly coupled heat pipes that form a single vapor core to facilitate the spreading and even storing of thermal energy. An ejector plate may be attached to the top of the second plate to create a low pressure zone as the heat source passes over it, thereby pulling the ambient air through the cellular core, facilitating the removal the thermal energy from the system.

Abstract: A direct vapor deposition (DVD) method and apparatus for applying coating(s) on substrate(s), including: presenting at least one of the substrates to a chamber, presenting at least one evaporant source (125) in crucible (110) to the chamber; presenting at least one carrier gas stream (105) to the chamber using a ring-shaped (133) converging/diverging nozzle (130); impinging at least one evaporant source with at least one electron beam in the chamber to generate an evaporated vapor flux in a main direction respective for any of the evaporant sources impinged by the electron beam; and guiding at least one of the generated evaporated vapor flux by at least one carrier gas stream from the ring shaped gap (132), which is essentially parallel to the main direction and substantially surrounds the evaporated flux. The evaporated vapor flux at least partially coats at least one of the substrates.

Abstract: The present invention relates to methods for forming one or more thin film layers on a substrate, to form a multilayer product such as a lithium battery cell. The method involves passing a gas stream comprising at least one doping agent and at least one entrained source material through a plasma; impinging the gas stream on a substrate; and reactively depositing the at least one doping agent, and the at least one entrained source material on the substrate. The present invention provides a method of fabricating a power cell having a plurality of layers, and a method of fabricating a battery by electrically connecting a current collecting layer of a first power cell to a current collecting layer of a second power cell.

Abstract: Light-weight, heat-managing structures feature open-cell lattice, honeycomb, and/or corrugated (prismatic) arrangements in their substructures, combined with heat pipe/heat plate arrangements for managing heat to which the structures are subjected. The structures are well suited to aerospace applications and may be employed in the leading edge of wings or other airfoil-shaped components; gas turbine engine components; rocket nozzles; and other high-heat, high-stress environments.

Abstract: A direct vapor deposition (DVD) apparatus and method is taught, that provides a carrier gas flow entraining vapor atoms for the coating of regions on a substrate that are not in line-of-sight. The degree of non line-of-sight (NLOS) coating, hence thickness uniformity around the substrate is a sensitive function of the flow conditions. For a fixed background pressure in the region of deposition, an increase in the uniformity of the coating thickness is accomplished as the flow velocity is reduced. This improvement in uniformity is a result of an increase in the fraction of vapor atoms which deposit in NLOS positions on the substrate such as backside (21) of fiber (65) as indicated by vapor streamlines (51). Vapor impact width (VIW) is the width of the vapor flux impacting on some area of the fiber. Front side coating (FSC) width is the vapor width of atoms impacting on the substrate frontside (22).

Abstract: An interwoven sandwich panel structure made for high intensity impulse mitigation comprises a top and bottom face panel integrally interwoven to a core by creating a preform from the interweaving of cross-wise and length-wise threads and then infusing it with a thermoset polymer resin such that it requires no stitching, bonding, or fastening to attach core to the face panels removing the primary weak points of a sandwich panel structure.

Abstract: A multifunctional member with a first active member (30), which is adapted to contract if exposed to a temperature above a first transition temperature range. A second active member (40), which is adapted to contract if exposed to a temperature above a second transition temperature range. A core member (20), which is adaptive for deformation. The first and second active members (30, 40) are attached on opposite or different sides of the core member (20). A heat source operatively connected to the first and second active members (30, 40) to expose them to transition temperatures. The first active member (30) contracts while above the first transition temperature range causing the second active member (40) to expand, wherein the second active member (40) is below the second transition temperature range.

Abstract: Methods and systems to manufacture bonded corrugation truss-based structures. This allows the ability to change the dimensions of the individual structural features of the corrugations, i.e. thickness of the core, face sheet thickness, relative density of the core, and the alloys. The nodal design which provides ideal stress/strain distribution for in-plane and out-off plane loading. The node has a curved/smooth triple point intersection which in turn can provide best load transfer interface with high integrity/toughness. The bonded corrugation truss based structure can be continuous to any length only limited by the volume of the extrusion billet and the press capacity. An aspect of the bonded corrugation structures may include friction stir welding of the face sheets or any fusion welding of panels with edge members for strengthening allows fabrication of panels of any width and length. Bonding panels enables the fabrication of structures of any width.

Abstract: Methods and systems to manufacture lattice-based sandwich structures from monolithic material. Such methods and systems eliminate the bonding process which is conventionally used to join lattice based truss cores to facesheets to form sandwich structures. This bonded interface is a key mode of failure for sandwich structures which are subjected to shear or bending loads because the nodes transfer forces from the face sheets to the core members while the topology for a given core relative density dictates the load carrying capacity (assuming adequate node-bond strength exists). An aspect comprises a core and related structures that provide very low density, good crush resistance and high in-plane shear resistance. An aspect of the truss structures may include sandwich panel cores and lattice truss topology that may be designed to efficiently support panel bending loads while maintaining an open topology that facilitates multifunctional applications.

Abstract: A sandwich panel core that may be comprised of a lattice structure utilizing a network of hierarchical trusses, synergistically arranged, to provide support and other functionalities disclosed herein. Since this design results in a generally hollow core, the resulting structure maintains a low weight while providing high specific stiffness and strength. Sandwich panels are used in a variety of applications including sea, land, and air transportation, ballistics, blast impulse mitigation, impact mitigation, thermal transfer, ballistics, load bearing, multifunctional structures, armors, construction materials, and containers, to name a few.

Abstract: Provided is a methodology and system for applying coatings onto the interior surfaces of components. The approach comprises a vapor creation device (for example an electron beam or laser that evaporates a single or multiplicity of solid or liquid sources), a vacuum chamber having a moderate gas pressure (between about 10?4 to about 103 Torr) and a inert gas jet having controlled velocity and flow fields of gas jet. The gas jet is created by a rarefied, inert gas supersonic expansion through a nozzle. By controlling the carrier gas flow into a region upstream of the nozzle an upstream pressure is achieved (i.e. the gas pressure prior to its entrance into the processing chamber through the nozzle). The carrier gas flow and chamber pumping rate control the downstream (or chamber) pressure (i.e., downstream of the nozzle). The ratio of the upstream to downstream pressure along with the size and shape of the nozzle opening controls the speed of the gas entering the chamber.

Abstract: A cellular material that can provide a unique combination of properties and characteristics for a variety of applications requiring a cellular solid that possesses one or more of the following characteristics: (1) efficient load support in one or more directions, (2) excellent mechanical impact energy absorption and vibration suppression potential, (3) high convection heat transfer throughout, (4) low pumping requirements for fluid throughput, for example in a second direction orthogonal to one or more load-bearing directions, (5) a substantially linear dependence of the Young's and shear moduli along with the tensile, compressive and shear yield strengths upon relative density (6) a potentially inexpensive textile-based synthetic approach, (7) excellent filtration potential, (8) a high surface area to volume ratio for enhanced activity as a catalyst or catalyst support (9) interconnected, open porosity for device storage, biological tissue in-growth or other functionalities requiring open space, and (10) ext

Abstract: An embodiment provides a method of constructing a cellular structure having nodes therein comprising: providing at least one truss layer comprised of at least one truss unit, at least one of the truss units being comprised of truss members; providing at least one panel in mechanical communication with the at least one truss unit of the at least one truss layer, the mechanical communication defines contact regions wherein the at least one truss unit is coupled to the at least one panel; the nodes being defined as intersections existing among any of the truss members and the nodes also being defined by the contact regions; providing at least one node pin, the at least one node pin spanning between two desired the nodes; and diffusion bonding at least one of the truss layer to the at least one panel.

Abstract: A method and apparatus for forming a thermal barrier coating system (90) in communication with at least a portion of at least one substrate (92). The method includes: depositing a first bond coat (94) on at least a portion of at least one substrate (92); depositing a first thermal barrier coat (96) disposed on the bond coat (94); whereby the deposition occurs in one or more chambers to form the thermal barrier coating system (90); and wherein the deposition of the first bond coat (94) (or subsequent bond coats) and the deposition of the first thermal barrier coat (96) (or subsequent thermal barrier coats) is performed without out-of-chamber handling of the thermal barrier coating system (90).

Abstract: A method and an apparatus for the efficient transfer of heat utilizing micro heat pipes that include a cellular foam or interconnected cellular/truss network having hollow ligaments. A predetermined fraction of the internal volume of the hollow ligaments is filled with a carefully chosen working fluid, and the ends of the hollow ligaments are sealed. In operation, the working fluid evaporates in the region of high heat flux and condenses in regions of lower temperature, resulting in the transfer or redistribution of the fluid's latent heat of vaporization. For open cell foams and interconnected networks, a second fluid flowing through the open cells, separate from the working fluid but also in thermal contact with the hollow ligaments, assists in the transfer of heat from the foam and networks.

Abstract: A method and an apparatus for the efficient transfer of heat utilizing micro heat pipes that include a cellular foam or interconnected cellular/truss network having hollow ligaments. A predetermined fraction of the internal volume of the hollow ligaments is filled with a carefully chosen working fluid, and the ends of the hollow ligaments are sealed. In operation, the working fluid evaporates in the region of high heat flux and condenses in regions of lower temperature, resulting in the transfer or redistribution of the fluid's latent heat of vaporization. For open cell foams and interconnected networks, a second fluid flowing through the open cells, separate from the working fluid but also in thermal contact with the hollow ligaments, assists in the transfer of heat from the foam and networks.

Abstract: Provided herein are methods and apparatuses, and resulting structures, for depositing ceramic coatings with preferred coating density, morphology and adherence for applications such as thermal protection of internally cooled components. Such components are found in, but not limited thereto, the hot sections of gas turbine and diesel engines and in turbo machinery. These coatings require a low thermal conductivity in the through thickness of the coating, high in-plane elastic compliance, high erosion and foreign object damage resistance and resistance to hot corrosion. The methods and apparatuses discussed herein provide, among other things, how to manipulate the process conditions in EB-DVD systems to deposit high quality, highly efficient TBS top coats as well as how to deposit high quality TBC top coats onto positions that are in the line-of-sight, as well as non-line of sight, of the vapor source.

Abstract: Multifunctional cellular metals (or other materials) for structural applications that are capable of recovering their original (undeformed) shape and thickness after impact or crushing (i.e., self-healing). Alternatively, they may normally be stored or used in their compressed (i.e., crushed) state and deployed when needed to act as energy absorbing structure or packaging (i.e., deployable energy absorber). Additionally, the multifunctional structures may act as an actuator, capable of providing localized or distributed force and displacement, and related methods of using and manufacturing the same. These active cellular metals (or other materials) are composites consisting of conventional metal/alloy truss structures (or other material structures) in combination with shape memory metal/alloy components (or other material components) and offer high specific strength and stiffness, but which are also deployable energy absorbers or self-healing smart structures.