System optimization using compressed reticulated foam structures

Abstract

Heterogeneously dense (relative density) continuous one-piece insoluble reticulated foam material with a continuous relative density gradient and/or distinct and marked relative densities and methods of manufacture.

1 .- 19 . (canceled) 
     
     
         20 . A heterogeneously dense continuous one-piece insoluble reticulated open-celled foam metal or alloy material comprising
 (a) partially collapsed open cells ranging in size and having a maximum diameter of 4 mm and a minimum diameter of 0.35 mm;   (b) ligaments having a width of 0.025 mm to 0.7 mm;   (c) pores formed by the ligaments; and   (d) a relative density gradient within the heterogeneously dense one-piece insoluble reticulated open celled foam metal or alloy material ranging from at least 3% in density at a least dense point to 85% density at a most dense point.   
     
     
         21 . The heterogeneously dense foam material of  claim 20 , wherein the relative density gradient is continuous across the one-piece insoluble reticulated open-celled foam metal or alloy material. 
     
     
         22 . The heterogeneously dense foam material of  claim 20 , wherein the relative density gradient is formed from the collapsing of the cells. 
     
     
         23 . The heterogeneously dense foam material of  claim 20 , wherein pores formed by the ligaments are deformed. 
     
     
         24 . The heterogeneously dense foam material of  claim 20 , wherein the relative density gradient occurs along a single direction. 
     
     
         25 . The heterogeneously dense foam material of  claim 20 , wherein the relative density gradient occurs across two directions. 
     
     
         26 . The heterogeneously dense foam material of  claim 20 , wherein the relative density gradient occurs across three dimensions. 
     
     
         27 . The heterogeneously dense foam material of  claim 20 , wherein the relative density within the foam material is a continuous gradient that ranges from 10% to 33% and all values therebetween. 
     
     
         28 . The heterogeneously dense foam material of  claim 20 , wherein the relative density within the foam material is a continuous gradient that ranges from 25% and 70%, and all values therebetween. 
     
     
         29 . The heterogeneously dense foam material of  claim 20 , wherein the relative density gradient within the foam has distinct and marked differences. 
     
     
         30 . The heterogeneously dense foam material of  claim 29 , wherein the relative density within the foam is 10%, 25%, and 33%. 
     
     
         31 . The heterogeneously dense foam material of  claim 29 , wherein the relative density within the foam is 25% and 33%. 
     
     
         32 . The heterogeneously dense foam material of  claim 20 , wherein the cell diameters have a maximum diameter of 3.72 mm and a minimum diameter of 0.55 mm. 
     
     
         33 . The heterogeneously dense foam material of  claim 20 , wherein the ligament width is 0.028 mm to 0.65 mm. 
     
     
         34 . The heterogeneously dense foam material of  claim 20 , wherein the pore size is 0.025 mm to 0.65 mm. 
     
     
         35 . A blunt trauma foam protection barrier comprising the heterogeneously dense foam material of  claim 20 . 
     
     
         36 . A heat exchanger comprising the heterogeneously dense foam material of  claim 20 . 
     
     
         37 . An energy absorber comprising the heterogeneously dense foam material of claim  1 . 
     
     
         38 . A filter comprising the heterogeneously dense foam material of claim  1 .