Macro-patterned materials and structures for vehicle arresting systems

Abstract

Embodiments of the present disclosure relate generally to macro-patterned materials and methods of their use in connection with vehicle arresting systems. Certain embodiments provide 3-D folded materials, honeycombs, lattice structures, and other periodic cellular material structures, that can be used for arresting vehicles. The materials can be engineered to have properties that allow them to reliably crush in a predictable manner under pressure from a vehicle. The materials can be formed into various shapes and combined in various ways in order to provide the desired properties.

What is claimed is: 
     
         1 . A vehicle arresting system, comprising:
 a plurality of macro-patterned structures formed of a material that reliably crushes in a predictable manner.   
     
     
         2 . The system of  claim 1 , wherein the macro-patterned structures comprise three dimensional folded structures. 
     
     
         3 . The system of  claim 2 , wherein the three dimensional folded structures are formed by pressing a sheet of material with one or more sets of rollers to form a desired raised pattern on the sheet. 
     
     
         4 . The system of  claim 2 , wherein the three dimensional folded structures comprise a chevron pattern. 
     
     
         5 . The system of  claim 2 , wherein the three dimensional folded structures are combined into a block, with one or more structures separated by an intermediate layer. 
     
     
         6 . The system of  claim 1 , wherein the macro-patterned structures comprise a uniform geometry throughout each structure. 
     
     
         7 . The system of  claim 1 , wherein the macro-patterned structures comprise a honeycomb cell structure bordered by one or more outer panels. 
     
     
         8 . The system of  claim 7 , wherein the honeycomb structure comprises a cell size of from about 0.25 inch to about five inches. 
     
     
         9 . The system of  claim 7 , wherein the one or more outer panels comprise one or more scores or cuts. 
     
     
         10 . The system of  claim 7 , wherein the honeycomb structure comprises cells having axes, wherein the cell axes are arranged in a non-perpendicular manner with respect to an arresting bed surface. 
     
     
         11 . The system of  claim 1 , wherein the macro-patterned structures comprise a raw material thickness of from about 0.003 inches to about 0.016 inches. 
     
     
         12 . The system of  claim 1 , wherein the macro-patterned structures comprise a height of about 0.3 inch to about 2 inches. 
     
     
         13 . The system of  claim 1 , wherein the macro-patterned structures comprise sheet metal, aluminum, copper, stainless steel, metal foil, plastic, paper, fire resistant-paper, paperboard, fiberboard, corrugated material, fiberglass, reinforced composite, carbon fiber, reinforced composite material, thermoplastic materials, ceramics, cementitious materials, polymers, or combinations thereof 
     
     
         14 . The system of  claim 1 , comprising a block formed from a plurality of macro-patterned structures, wherein the macro-patterned structures at the top of the block have a lower strength than the macro-patterned structures at the bottom of the block. 
     
     
         15 . The system of  claim 1 , wherein the macro-patterned structures comprise lattice structures having a density in the range of about 2-50 pcf and a compressive strength in the range of 3-100 psi. 
     
     
         16 . The system of  claim 1 , wherein the macro-patterned structures comprise lattice structures having a component diameter or component cross-section feature size of about 0.001 to about 1.5 inches. 
     
     
         17 . A vehicle arresting system, comprising:
 a plurality of macro-patterned structures formed as three dimensional folded structures that are stacked with respect to one another and separated by one or more intermediate layers,   wherein the material of the structures comprises a material that reliably crushes in a predictable manner, and   wherein the macro-patterned structures comprise a raw material thickness of from about 0.003 inches to about 0.016 inches and a patterned layer height of about 0.3 inch to about 12 inches.