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

Patent metadata

Field	Value
Publication number	US-9868667-B2
Application number	US-201213411218-A
Country	US
Kind code	B2
Filing date	Mar 2, 2012
Priority date	Mar 5, 2011
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

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 bonding matrix comprising a plurality of bonding elements, each bonding element comprising:
a core, wherein the core has a first chemical composition that includes one or more chemical elements;
a silica-rich first layer at least partially covering a peripheral portion of the core; and
a calcium carbonate and/or magnesium carbonate-rich second layer at least partially covering a peripheral portion of the first layer,
wherein the bonding matrix is prepared from a porous solid body, the porous solid body comprises a plurality of precursor particles, the precursor particles have a mean particle size of less than 70 μm, and the precursor particles are transformed into the bonding elements,
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 comprises silicon.

2. The bonding matrix of claim 1 , wherein the first chemical composition includes at least two different chemical elements, wherein cations associated with the silica-rich first layer correspond to a first one of the at least two different chemical elements of the first chemical composition, and wherein cations associated with the calcium carbonate and/or magnesium carbonate-rich second layer correspond to a second one of the at least two different chemical elements of the first chemical composition.

3. The bonding matrix of claim 1 , wherein the first chemical composition includes at least two different chemical elements, wherein cations associated with the silica-rich first layer correspond to a first one of the at least two different chemical elements of the first chemical composition, and wherein cations associated with the calcium carbonate and/or magnesium carbonate-rich second layer correspond to the first one of the at least two different chemical elements of the first chemical composition.

4. The bonding matrix of claim 1 , wherein the first chemical composition includes only one chemical element.

5. The bonding matrix of claim 1 , wherein cations associated with the silica-rich first layer are bonded with anions corresponding to one of the chemical elements of the first chemical composition.

6. The bonding matrix of claim 5 , wherein cations associated with the calcium carbonate and/or magnesium carbonate-rich second layer are bonded with anions corresponding to a reactant.

7. The bonding matrix of claim 1 , wherein cations associated with the silica-rich first layer are bonded with anions corresponding to a first reactant.

8. The bonding matrix of claim 7 , wherein cations associated with the calcium carbonate and/or magnesium carbonate-rich second layer are bonded with anions corresponding to a second reactant.

9. The bonding matrix of claim 1 , wherein the core is equiaxed.

10. The bonding matrix of claim 1 , wherein the core is elliptically-shaped.

11. The bonding matrix of claim 1 , wherein the core is fiber-shaped.

12. The bonding matrix of claim 1 , wherein the first layer is an amorphous layer.

13. The bonding matrix of claim 1 , wherein the core has a symmetrical shape.

14. The bonding matrix of claim 1 , wherein the core has a non-symmetrical shape.

15. The bonding matrix of claim 1 , wherein the core is in the shape of a flake.

16. The bonding matrix of claim 1 , wherein the core comprises CaSiO 3 .

17. The bonding matrix of claim 1 , wherein the core comprises MgSiO 3 .

18. The bonding matrix of claim 1 , wherein the first layer is a crystalline layer.

19. The bonding matrix of claim 1 , wherein the first layer comprises an oxide or a hydroxide of silicon.

20. The bonding matrix of claim 1 , wherein the first layer comprises silicon oxide.

21. The bonding matrix of claim 1 , wherein the first layer comprises silicon hydroxide.

22. The bonding matrix of claim 1 , wherein the second layer is composed of the carbonate bonds with one or more active particulates selected from the group consisting of limestone, marble dusts, calcium carbonate rich aggregates, gypsum, sand, silica rich aggregates, and combinations thereof.

23. The bonding matrix of claim 1 , wherein the second layer is a continuous phase or discontinuous phase.

24. The bonding matrix of claim 1 , wherein the bonding matrix is porous.

25. The bonding matrix of claim 1 , wherein the bonding elements are oriented in the 1-D orientation, 2-D orientation, 3-D orientation, randomly oriented, or form a percolation network.

26. The bonding matrix of claim 1 , wherein at least some of the bonding elements are in contact with one another.

27. The bonding matrix of claim 1 , wherein the second layer is composed of CaCO 3 which bonds with one or more active particulates selected from the group consisting of limestone, marble dusts, calcium carbonate rich aggregates, gypsum, sand, silica rich aggregates, and combination thereof.

28. The bonding matrix of claim 1 , further comprising a hydrate-free cementitious bond.

29. A composite material comprising:
the bonding matrix according to claim 1 ; and
a filler material incorporated in the bonding matrix.

30. The composite material of claim 29 , wherein the filler material includes an inert material.

31. The composite material of claim 30 , wherein the inert material comprises a plurality of equiaxed particles.

32. The composite material of claim 30 , wherein the inert material comprises a plurality of anisotropic particles.

33. The composite material of claim 30 , wherein the inert material comprises a combination of equiaxed particles and anisotropic particles.

34. The composite material of claim 29 , wherein the filler material includes an active material.

35. The composite material of claim 34 , wherein the active material comprises a plurality of equiaxed particles.

36. The composite material of claim 34 , wherein the active material comprises a plurality of anisotropic particles.

37. The composite material of claim 34 , wherein the active material comprises a combination of equiaxed particles and anisotropic particles.

38. The composite material of claim 29 , wherein the filler material comprises:
a first plurality of first size particles and a second plurality of second size particles, the second size 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.

39. The composite material of claim 38 , wherein the bonding matrix is substantially arranged in porous spaces between adjacent first size particles, and wherein the adjacent first size particles are arranged in porous spaces between adjacent second size particles.

40. The composite material of claim 39 , wherein the bonding matrix at least partially covers a peripheral portion of each of the adjacent first size particles.

41. The composite material of claim 29 , wherein the bonding elements are aligned in a 1-D orientation.

42. The composite material of claim 29 , wherein the bonding elements are

Assignees

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

Inventors

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

Classifications

• C04B20/12

  Multiple coating or impregnating · CPC title

• C04B28/04

  Portland cements · CPC title

• Y10T428/249953

  Composite having voids in a component [e.g., porous, cellular, etc.] · CPC title

• C04B2111/29

  Frost-thaw resistance · CPC title

• Y10T428/24851

  Intermediate layer is discontinuous or differential · CPC title