Organic-inorganic composites and methods of manufacturing thereof

Patent metadata

Field	Value
Publication number	US-2022016854-A1
Application number	US-201917258958-A
Country	US
Kind code	A1
Filing date	Jun 24, 2019
Priority date	Jul 9, 2018
Publication date	Jan 20, 2022
Grant date	—

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.

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 or claim 2 , wherein the inorganic glass has a glass transition temperature in a range of 200° C. to 450° C., and the polymer is a thermoplastic polymer.

4 . The composite of any one of claims 1 - 3 , 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 any one of claims 1 - 4 , 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, flourophosphates, 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 any one of claims 1 - 5 , wherein the polymer comprises at least one of polyetherimide (PEI), polyethersulfone (PES), polyphenylsulfone (PPS), or a combination thereof.

7 . The composite of any one of claims 1 - 6 , wherein the inorganic glass domain is a shape comprising at least one of a two-dimensional planar layer, fiber, filament, ribbon, sphere, brick, platelet, or a combination thereof.

8 . The composite of any one of claims 1 - 7 , wherein:
the inorganic glass domain 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.

9 . The composite of any one of claims 1 - 8 , wherein the inorganic glass domain comprises a plurality of cylindrical filaments having a diameter in a range of 50 nm to 400 nm separated by a continuous polymer domain.

10 . The composite of any one of claims 1 - 9 , wherein the inorganic glass domain 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.

11 . The composite of any one of claims 1 - 10 , 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. %.

12 . The composite of any one of claims 1 - 11 , 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 0 metal, ammonium phosphates, or combinations thereof.

13 . The composite of any one of claims 1 - 12 , wherein at least 90% of the inorganic glass domains have a length of less than 30 μm as measured along the at least one cross-sectional dimension.

14 . The composite of any one of claims 1 - 13 , wherein at least 90% of the inorganic glass domains have a length of less than 10 μm as measured along the at least one cross-sectional dimension.

15 . The composite of any one of claims 1 - 14 , 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.

16 . The composite of any one of claims 1 - 15 , 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.

17 . A method of forming an organic-inorganic composite, comprising:
melting at a suitable temperature, a tin composite oxide material and a boron-containing material; pouring or extruding the product of the melting into a rod and annealing the rod to form an annealed glass rod; encapsulating the annealed glass rod in a thermoplastic polymer to form a glass-polymer structure; heating the glass-polymer structure at a temperature above the glass transition temperature (T g ) or softening temperature of both the glass rod and the thermoplastic polymer to form a preform; drawing the preform to form a first drawn fiber having a first diameter; bundling the first drawn fiber into a first array comprising a plurality of the first drawn fibers; and heat treating the plurality of fibers to form the organic-inorganic composite.

18 . The method of claim 17 , wherein the tin composite oxide comprises at least one of Sn 2 P 2 O 7 , SnO, Sn 2+ -containing oxides, or combinations thereof.

19 . The method of claim 17 or claim 18 , wherein the thermoplastic polymer comprises at least one of polyetherimide (PEI), polyethersulfone (PES), polyphenylsulfone (PPS), or a combination thereof.

20 . The method of any one of claims 17 - 19 , wherein the heating is conducted at a temperature in a range of 200° C. to 450° C.

21 . The method of any one of claims 17 - 20 , wherein heat treating the drawn fiber comprises heating at a temperature in a range of 250° C. to 350° C. for a time in a range of 1 hr to 20 hrs in a vacuum or inert environment.

22 . The method of any one of claims 17 - 21 , further comprising:
a second drawing to form a second drawn fiber having a second diameter; and a second bundling of the second drawn fiber to form a second array comprising a plurality of the second drawn fibers, wherein the second diameter is less than the first diameter.

23 . The method of claim 22 , further comprising:
a third drawing to form a third drawn fiber having a third diameter; and a third bundling of the third drawn fiber to form a third array comprising a plurality of the third drawn fibers, wherein the third diameter is less than the second diameter.

24 . The method of any one of claims 17 - 23 , further comprising:
hot-pressing the organic-inorganic composite at a temperature in a range of 300° C. to 500° C., wherein a temperature gradient is formed between a surface of the composite in contact with the hot press and a distance into the composite not in contact with the hot press.

Assignees

• Corning Inc

Inventors

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

Classifications

• C03C2213/00

  Glass fibres or filaments · CPC title

• C03C13/00

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

• B29K2081/06

  PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof · CPC title

• B29K2079/085

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

• B29C70/20 Primary

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