Organic-inorganic composites and methods of manufacturing thereof

Patent metadata

Field	Value
Publication number	US-11993028-B2
Application number	US-201917258958-A
Country	US
Kind code	B2
Filing date	Jun 24, 2019
Priority date	Jul 9, 2018
Publication date	May 28, 2024
Grant date	May 28, 2024

Abstract

A composite has repeating domains of an inorganic glass and a polymer, such that the inorganic glass and the polymer each have a glass transition temperature (Tg) or softening temperature of less than 450° C., and at least 50% of the inorganic glass domains have a length of less than 30 μm as measured along at least one cross-sectional dimension.

First claim

What is claimed is:

1. A composite having repeating domains of an inorganic glass and a polymer,
wherein the inorganic glass and the polymer each have a glass transition temperature (T g ) or softening temperature of less than 450° C.,
wherein at least 50% of the inorganic glass domains have a length of less than 30 μm as measured along at least one cross-sectional dimension,
wherein at least one of the inorganic glass domains comprises a plurality of cylindrical filaments having a diameter in a range of 50 nm to 400 nm separated by a continuous polymer domain, and
the composite has 50% or more of the inorganic glass by volume of the composite.

2. The composite of claim 1 , wherein the inorganic glass domains have an average length as measured along at least one cross-sectional dimension, and wherein at least 90% of the inorganic glass domains have a length as measured along at least one cross-sectional dimension within 50% of the average length.

3. The composite of claim 1 , wherein the inorganic glass has a glass transition temperature in a range of 200° C. to less than 450° C., and the polymer is a thermoplastic polymer.

4. The composite of claim 1 , wherein the inorganic glass comprises at least one of an oxide glass, a fluoride glass, an oxyfluoride glass, a phosphate glass, a borate glass, a germanate glass, a tellurite glass, a vanadate glass, or combinations thereof.

5. The composite of claim 1 , wherein the inorganic glass comprises at least one of alkali-zinc sulfophosphates, tin borophosphates, zinc phosphates, zinc borophosphates, tin phosphates, zinc borates, bismuth borates, zinc bismuth borates, tin-zinc borophophates, antimony germanates, tellurites, tellurium vanadates, fluorophosphates, tin fluorophosphates, alkali fluorophosphates, alkali-aluminum fluorophosphates, alkali-tantalum borophosphates, tin silicates, alkaline earth aluminoborates, alkali aluminophosphates, alkaline earth aluminophosphates, alkali borophosphates, alkali-zinc phosphates, alkali-tin-zinc phosphates, alkali-aluminum borophosphates, or combinations thereof.

6. The composite of claim 1 , wherein the polymer comprises at least one of polyetherimide (PEI), polyethersulfone (PES), polyphenylsulfone (PPS), or a combination thereof.

7. The composite of claim 1 , wherein:
at least one of the inorganic glass domains is a discontinuous phase comprising a plurality of adjacent and similarly oriented fibers of an inorganic material,
the polymer domain is a continuous phase surrounding the plurality of adjacent and similarly oriented fibers of the inorganic material, and
the composite is a plurality of adjacent and similarly oriented fibers of inorganic material contained within a similarly oriented host fiber of the polymer.

8. The composite of claim 1 , wherein at least one of the inorganic glass domains further comprises at least one of cylindrical structures, layers, platelets, brick-like structures, or a combination thereof having a domain characteristic length in a range of 0.1 μm to 3 μm.

9. The composite of claim 1 , wherein the inorganic glass comprises:
a B 2 O 3 component at a concentration in a range of 0.5 wt. % to 10 wt. %;
a P 2 O 5 component at a concentration in a range of 30 wt. % to 40 wt. %; and
a SnO component at a concentration in a range of 60 wt. % to 70 wt. %.

10. The composite of claim 1 , the inorganic glass comprises less than 10 mol. % of a glass additive, the additive including at least one of SiO 2 , Al 2 O 3 , TiO 2 , WO 3 , CeO 2 , CaO, BaO, SrO, SO 3 , MoO 3 , SnO, SnF 2 , Sn metal, ammonium phosphates, or combinations thereof.

11. The composite of claim 1 , wherein at least 90% of the inorganic glass domains have a length of less than 5 μm as measured along the at least one cross-sectional dimension.

12. The composite of claim 1 , wherein at least 90% of the inorganic glass domains have a length of less than 1 μm as measured along the at least one cross-sectional dimension.

13. A composite having repeating domains of an inorganic glass and a polymer,
wherein the inorganic glass and the polymer each have a glass transition temperature (T g ) or softening temperature of less than 450° C.,
wherein at least 50% of the inorganic glass domains have a length of less than 30 μm as measured along at least one cross-sectional dimension, and
wherein at least one of the inorganic glass domains is a fiber having a length-to-diameter ratio of greater than 100, and the fiber has a diameter less than 2 μm.

14. The composite of claim 13 , wherein the composite has 50% or more of the inorganic glass by volume of the composite.

15. The composite of claim 13 , the diameter of the fiber is in a range of 50 nm to 400 nm.

16. The composite of claim 13 , wherein the inorganic glass and the polymer each have a glass transition temperature (T g ) or softening temperature in a range of 200° C. to 300° C.

17. The composite of claim 13 , wherein at least 90% of the inorganic glass domains have a length of less than 1 μm as measured along the at least one cross-sectional dimension.

18. The composite of claim 13 , wherein the polymer comprises at least one of polyetherimide (PEI), polyethersulfone (PES), polyphenylsulfone (PPS), or a combination thereof.

Assignees

• Corning Inc

Inventors

• Decker Heather Bossard
• Hart Shandon Dee
• Li Yanfei
• Mccarthy Joseph Edward
• Mcenroe David John
• Quesada Mark Alejandro

Classifications

• B29C70/20 Primary

  oriented in a single direction, e.g. roofing or other parallel fibres {(B29C70/083, B29C70/226 take precedence)} · CPC title

• C03C3/19 Primary

  containing boron · CPC title

• C03C13/00

  Fibre or filament compositions (manufacture of fibres or filaments C03B37/00) · CPC title

• B29K2079/085

  Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof · CPC title

• B29K2081/04

  Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof · CPC title