Bonding element, bonding matrix and composite material having the bonding element, and method of manufacturing thereof

Patent metadata

Field	Value
Publication number	US-2019202736-A1
Application number	US-201916257544-A
Country	US
Kind code	A1
Filing date	Jan 25, 2019
Priority date	Mar 5, 2011
Publication date	Jul 4, 2019
Grant date	—

Abstract

A bonding element, a bonding element matrix and composite materials with a wide range of attractive properties that may be optimized, including, but not limited to, mechanical properties, thermal properties, magnetic properties, optical properties and nuclear properties, as a result of a first layer and second layer structure or core, first layer, and second layer structure of the bonding elements, as well as methods for making the bonding elements and the corresponding ceramic and/or composite materials.

First claim

What is claimed is:

1 . A method of manufacturing a composite material, said method comprising:
providing a precursor material that comprises a plurality of precursor particles, the precursor material having some degree of porosity; introducing a liquid solvent into the pores of the precursor material; and introducing a gaseous reactant into the pores of the precursor material, whereby the precursor particles are transformed into bonding elements, wherein the composite material comprises: a bonding matrix, and
a filler material incorporated in the bonding matrix, the bonding matrix comprising a plurality of the bonding elements, each of the bonding elements comprising:
a core;
a first layer at least partially covering a peripheral portion of the core; and
a second layer at least partially covering a peripheral portion of the first layer, and

wherein the core comprises at least one synthetic formulation having chemical elements M, Me, and O (oxygen) and/or OH group, M is an alkaline earth metal selected from calcium or magnesium, and Me is selected from a group of metals consisting of silicon, titanium, aluminum, phosphorous, vanadium, tungsten, molybdenum, gallium, manganese, zirconium, germanium, copper, niobium, cobalt, lead, iron, indium, arsenic and tantalum.

2 . The method of claim 1 , wherein the at least a portion of the precursor particles do not react with the reactant and remain to form the core of the bonding elements.

3 . The method of claim 1 , wherein a remainder of the precursor particles are transformed to form a first and second layers, thereby leaving no precursor particles in the bonding elements.

4 . The method of claim 1 , wherein introducing a liquid solvent into the pores of the precursor material comprises partially filling the pores of the precursor material with the liquid.

5 . The method of claim 4 , wherein introducing a liquid solvent into the pores of the
precursor material further comprises: vaporizing the liquid; condensing the liquid in such a way that the liquid is distributed throughout the pores of the precursor material.

6 . The method of claim 1 , further comprising mixing the precursor material with a filler material.

7 . The method of claim 6 , wherein the filler material comprises: a first plurality of first size particles and a second plurality of second size particles, the second particles being substantially larger in size than the first sized particles, and wherein the bonding matrix, the first size particles and the second size particles are arranged such that the composite material forms a hierarchic structure.

8 . The method of claim 1 , wherein providing a precursor material that comprises a plurality of precursor particles comprises aligning the precursor particles in a desired orientation.

9 . The method of claim 1 , wherein aligning the precursor particles in a desired orientation comprises aligning the precursor particles in a 1-D orientation.

10 . The method of claim 1 , wherein aligning the precursor particles in a desired orientation comprises aligning the precursor particles in a 2-D orientation.

11 . The method of claim 1 , wherein aligning the precursor particles in a desired orientation comprises aligning the precursor particles in a 3-D orientation.

12 . The method of claim 1 , wherein providing a precursor material that comprises a plurality of precursor particles comprises arranging the precursor particles in a random orientation.

13 . A method of making a bonding element, comprising:
(i) providing a reactive precursor; (ii) transforming at least a portion of the reactive precursor to form a first layer over at least a portion of the non-transformed portion of the precursor and a second layer over at least a portion of the first layer, whereby a bonding element is formed; wherein the bonding element comprises: a core, which is the non-transformed portion of the precursor, and comprises at least one synthetic formulation having chemical elements M, Me, and O (oxygen) and/or OH group, M is an alkaline earth metal selected from calcium or magnesium, and Me is selected from a group of metals consisting of silicon, titanium, aluminum, phosphorous, vanadium, tungsten, molybdenum, gallium, manganese, zirconium, germanium, copper, niobium, cobalt, lead, iron, indium, arsenic and tantalum, wherein the first layer comprises a silica-rich layer, and wherein the second layer comprises a calcium carbonate and/or magnesium carbonate-rich layer.

14 . The method of claim 13 , wherein the transformation is via a disproportionation reaction.

Assignees

• Univ Rutgers

Inventors

• Riman Richard E
• Gupta Surojit
• Atakan Vahit
• Li Qinghua

Classifications

• C04B2111/2015

  Sulfate resistance · CPC title

• C04B28/04

  Portland cements · CPC title

• C04B28/188

  the Ca-silicates being present in the starting mixture · CPC title

• C04B14/465 Primary

  Ca-silicate, e.g. wollastonite · CPC title

• C04B28/10

  Lime cements or magnesium oxide cements · CPC title