Composite material, components comprising same and method of using same

Patent metadata

Field	Value
Publication number	US-10494309-B2
Application number	US-201615746835-A
Country	US
Kind code	B2
Filing date	Aug 17, 2016
Priority date	Aug 20, 2015
Publication date	Dec 3, 2019
Grant date	Dec 3, 2019

Abstract

A composite material comprising 50 to 95 mass % grains of primary material selected from the group consisting of talc, mica, graphite and hexagonal boron nitride, and 0.01 to 40 mass % fibers having a length of 0.05 to 20 mm, and a ratio of length to diameter of at least 5. The grains of the primary material have a mean size of 3 to 50 microns.

First claim

The invention claimed is:

1. Composite material comprising
50 to 95 mass % grains of primary material, in which the primary material consists of talc;
grains of secondary material comprising silicon carbide, zircon, mullite or garnet; and
0.01 to 40 mass % fibres having
a mean length of 0.05 to 20 mm, and
a ratio of length to diameter of at least 5; in which

the grains of the primary material have a mean size of 3 to 150 microns; and
the fibres consist of any of carbon, SiC and alumina.

2. The composite material as claimed in claim 1 ,
wherein the fibres have a mean length of at least 0.1 mm, the ratio of length to diameter is at least 10 and the grains of the primary material have a mean size of 5 microns.

3. The composite material as claimed in claim 1 , comprising 0.01 to 40 mass % grains of a secondary material comprising material selected from the group consisting of ceramic material, cubic boron nitride (cBN) or diamond.

4. The composite material as claimed in claim 3 , in which the secondary hard material grains have a mean size of 1 to 200 microns.

5. The composite material as claimed in claim 1 , in which the mean length of the fibres is at least 20 times their mean diameter.

6. The composite material as claimed in claim 1 , comprising at least 0.1 mass % fibres, and in which the fibres have a mean length of at least 0.5 mm.

7. The composite material as claimed in claim 1 , in which the fibres are in the form of continuous fibres, tangled fibres, multi-fibres, single fibres, or chopped fibres.

8. The composite material as claimed in claim 1 , in which at least 50% of the fibres have a length within 20% of the mean length of the fibres.

9. The composite material as claimed in claim 1 , comprising inorganic binder material.

10. The composite material as claimed in claim 1 , in which the fibres consist of carbon.

11. The composite material as claimed in claim 1 , comprising
grains of cBN crystals having a mean size of at least 10 microns.

12. The composite material as claimed in claim 1 ,
in the form of a compact having
density of at least 95% of the theoretical density of its constituent materials, the density contribution of each material weighted according to its mass % in the composite material.

13. The composite material as claimed in claim 1 ,
in the form of a non-bonded aggregation of powder grains.

14. A component comprising composite material as claimed in claim 1 .

15. A component as claimed in claim 14 , for a capsule for an ultra-high pressure press, comprising
a gasket, a containment vessel, an electrically conducting heater element, an electrical insulation component, or a reaction compact.

16. A component as claimed in claim 14 , consisting of
a gasket for a belt-type press, a tetrahedral-type press or a cubic-type press for pressurising a reaction assembly at an ultra-high pressure of at least 1 GPa;
comprising composite material as claimed in claim 1 .

17. A component as claimed in claim 14 , consisting of
a heater element for a belt-type press, a tetrahedral-type press or a cubic-type press for pressurising a reaction assembly at an ultra-high pressure of at least 1 GPa;
comprising composite material as claimed in claim 11 .

18. A component as claimed in claim 14 , consisting of
a reaction compact for synthesising cBN crystals in a belt-type press, a tetrahedral-type press or a cubic-type press for pressurising a reaction assembly at an ultra-high pressure of at least 1 GPa;
comprising composite material as claimed in claim 1 .

19. A method of using a component as claimed in claim 14 , in which
the component is for a capsule assembly for an ultra-high pressure press, and
the method includes
assembling a capsule including the component within the ultra-high pressure press, and
using the ultra-high pressure press to pressurise at least a volume of the capsule assembly to at least 1 GPa.

20. A method of using a component as claimed in claim 19 , in which
the component consists of a gasket for a belt-type ultra-high pressure press comprising a pair of opposable anvils and a die, and
the method includes
providing a pair of the components; and
assembling the capsule assembly within the die, in which each component is placed against a respective end of the die.

21. A method of using a component as claimed in claim 19 , in which
the component consists of a gasket for a cubic-type ultra-high pressure press, comprising three pairs of opposable anvils, and
the method includes
assembling the capsule assembly including the component between all three pairs of anvils.

Assignees

• Element Six Uk Ltd

Inventors

• Sani Mohammad Najafi
• Zhang Xiaoxue
• Mukherji Suchi Subhra

Classifications

• C04B35/522

  Graphite (C04B35/536 takes precedence) · CPC title

• C04B2235/5264

  characterised by the diameter of the fibers · CPC title

• C04B35/20

  rich in magnesium oxide {, e.g. forsterite (C04B35/195 takes precedence)} · CPC title

• C04B35/583

  based on boron nitride · CPC title

• C04B35/16

  based on silicates other than clay {(zircon C04B35/48)} · CPC title