Composite materials with tailored electromagnetic spectral properties, structural elements for enhanced thermal management, and methods for manufacturing thereof

• US 10,280,626 B2
• Filed: 08/20/2015
• Issued: 05/07/2019
• Est. Priority Date: 08/25/2014
• Status: Active Grant

• Current Assignee: O'Daniels LLC
• Original Assignee: Andreas Hieke, Ii, William Boone Daniels
• Inventors: Hieke, Andreas, Daniels, II, William Boone
• Primary Examiner(s): Pyon, Harold Y
• Assistant Examiner(s): Kang, Danny N
• Application Number:
  US14/831,813
• Publication Number:
  US 20160053481A1
• Time in Patent Office: 1,356 Days
• Field of Search: 252500
• CPC Class Codes: C04B 14/042 Magnesium silicates, e.g. talc, sepiolite
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/30 Oxides other than silica ferrites C04B14/363
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/305 Titanium oxide, e.g. titanates
• CPC Class Codes: C04B 14/308 Iron oxide
• CPC Class Codes: C04B 14/36 Inorganic materials not provided for in groups C04B14/022 and C04B14/04 - C04B14/34
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2111/00008 Obtaining or using nanotechnology related materials
• CPC Class Codes: C04B 2111/00258 Electromagnetic wave absorbing or shielding materials
• CPC Class Codes: C04B 2111/00482 Coating or impregnation materials
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 26/06 Acrylates
• CPC Class Codes: C04B 26/08 containing halogen
• CPC Class Codes: C04B 26/12 Condensation polymers of aldehydes or ketones
• CPC Class Codes: C04B 26/16 Polyurethanes
• CPC Class Codes: C04B 40/0268 Heating up to sintering temperatures C04B41/0072 takes precedence
• CPC Class Codes: C09D 5/032 characterised by a special effect of the produced film, e.g. wrinkle, pearlescence, matt finish
• CPC Class Codes: E04B 2001/7691 : Heat reflecting layers or coatings
• CPC Class Codes: E04F 13/02 : of plastic materials hardening after applying, e.g. plaster surface treatment in painting technique B44D; inorganic or bituminous masses C04B; organic plastics C08L ; implements for applying plasticised materials E04F21/02
• CPC Class Codes: H01B 1/00 : Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
• CPC Class Codes: H01B 1/20 : Conductive material dispersed in non-conductive organic material organic macromolecular compounds or compositions C08

Abstract

Disclosed is a method to produce composite materials, which contain customized mixes of nano- and/or micro-particles with tailored electromagnetic spectral properties, structural elements based thereon, in particular layers, but also bulk materials including inhomogeneous bulk materials. In some embodiments the IR-reflectivity is enhanced predominantly independently of reflectivity for visible wavelength. The enhanced IR-reflectivity is achieved by combining spectral properties from a plurality of nano- and/or micro-particles of distinct size distribution, shape distribution, chemical composition, crystal structure, and crystallinity distribution. This enables to approximate desired target spectra better than know solutions, which comprise only a single type of particles and/or an uncontrolled natural size distribution. Furthermore disclosed are methods of manufacturing such materials, including ceramics, clay, and concrete, as well as applications related to design and construction of buildings or other confined spaces.

Claims

1. A method of creating a composite material, comprising:

providing a plurality of distinct populations of nano- or micro-particles and/or of nano- or micro-cavities, a first population of said plurality of distinct populations comprising one or more of distinct size distributions, shape distributions, chemical compositions, crystal structures, and crystallinity distributions, relative to a second population of said plurality of distinct populations;

forming a composite material by embedding a mixture of the first population and the second population in a carrier material,

wherein forming comprises selecting a composition ratio of the first population to the second population, and selecting the density of the mixture relative to the carrier material, such that a specific targeted broadband spectral reflectance at least within the VIS and NIR range is approximated as a result of interference effects between at least some of the nano- or micro-particles and/or nano- or micro-cavities of the plurality of distinct populations,

wherein the specific targeted broadband spectral reflectance is different from that of each individual population within the plurality of populations and the carrier.

2. The method according to claim 1, further comprising:

providing a plurality of reservoirs R_i, with i defined as an integer ranging from 1 to k, corresponding to said plurality of said populations of nano- or micro-particles and/or of nano- or micro-cavities;

determining the composition ratios of said plurality of populations of nano- or micro-particles and/or of nano- or micro-cavities by performing an experimental optimization loop comprising at least the following steps;

A. creating a mixture of said populations of nano- or micro-particles and/or nano- or micro-cavities based on taking portions c_i from each reservoir R_i, wherein c_i shall denote the relative contribution of nano- or micro-particles and/or nano- or micro-cavities from each corresponding reservoir R_i to the mixture, thus all scalars c_i forming a composition vector denoted c,

B. embedding said mixture of said nano- or micro-particles and/or nano- or micro-cavities in the carrier material thereby creating the composite material,

C. using an amount of said composite material to determine a broadband spectral reflectance of the composite material at least within VIS and NIR, and

D. determining a quantity, which is a measure for the degree with which the broadband spectral reflectance of the composite material produced during step B does match the specific targeted broadband spectral reflectance,

E. determining if a predetermined threshold of said quantity has been reached, wherein the predetermined threshold measures the degree with which the broadband spectral reflectance of the composite material produced during step B does match the specific targeted broadband spectral reflectance, and;

E.1 if said threshold is not reached, having an optimization algorithm determine a new composition vector _j+1c of the mixture of said nano- or micro-particles and/or nano- or micro-cavities based on portions _j+1c_i taken from each reservoir R_i during a next iterative step j+1 and continuing the iteration of the optimization loop at step A; and

E.2 if said threshold is reached or surpassed, producing larger quantities of said composite material for subsequent use.

3. The method according to claim 1, further comprising:

determining the composition of said plurality of populations of nano- or micro-particles and/or of nano- or micro-cavities by performing an optimization loop which is based on computational modeling wherein the spectral performance of the composite material at least within the VIS and NIR range is determined by computations, and wherein after said composition has been computationally determined, said composites are produced in larger quantities for subsequent use.

4. The method according to any one of claims 1-3,

wherein providing comprises distributing said plurality of populations of nano- or micro-particles and/or of nano- or micro-cavities throughout the carrier material with spatially constant density.

5. The method according to any one of claims 1-3,

wherein providing comprises distributing said plurality of populations of nano- or micro-particles and/or of nano- or micro-cavities throughout the carrier material with higher density in regions close to the surface of the composite material compared to the inner regions of the composite material.

6. The method according to claim 5, further comprising applying said plurality of populations of nano- or micro-particles to surface areas of the carrier material while the carrier material is liquid or gel-like and thereby achieving an embedding of said particles, and wherein the carrier material subsequently solidifies, thus embedding said particles.

7. The method according to any one of claims 1-3,

wherein providing comprises distributing said plurality of populations of nano- or micro-particles and/or of nano- or micro-cavities throughout a liquid or gel-like carrier material,

applying the thereby formed liquid or gel-like composite material onto the surface of a solid material, having the thereby formed layer subsequently solidify, and

applying said composite with at least such thickness that opaqueness of said layer is achieved at least within the VIS and NIR range.

8. The method according to any one of claims 1-3, with a broadband highly reflective spectrum within the VIS and NIR range.

9. The method according to any one of claims 1-3, with a broadband highly reflective spectrum within the UV, VIS and NIR range.

10. The method according to any one of claims 1-3, with a broadband highly reflective spectrum within the VIS and NIR range, and a highly absorbing spectrum in the MIR.

11. The method according to any one of claims 1-3, with a broadband highly reflective spectrum at least within the VIS and NIR range, and a highly absorbing spectrum in the MIR and FIR.

12. The method according to any one of claims 1-3, further comprising choosing the specific targeted broadband spectral reflectance with a specific chosen reflective spectrum within the VIS range and a broadband highly reflective spectrum in the NIR range.

13. The method according to any one of claims 1-3, further comprising choosing the specific targeted broadband spectral reflectance with a specific chosen reflective spectrum within the VIS range and a broadband highly reflective spectrum in the UV and NIR range.

14. The method according to any one of claims 1-3, further comprising choosing the specific targeted broadband spectral reflectance with a specific chosen reflective spectrum within the VIS range and a broadband highly reflective spectrum in the NIR range and a broadband highly absorbing spectrum in the MIR range.

15. A method of using a composite material produced according to claim 8 on the surface of a open structure to reduce the amount of incident electromagnetic radiation which is converted to thermal energy.

16. A method of using a composite material produced according to claim 9 on the surface of a open structure to reduce the amount of incident electromagnetic radiation which is converted to thermal energy.

17. A method of using a composite material produced according to claim 8 on the surface of a closed structure to reduce the amount of incident electromagnetic radiation which is converted to thermal energy and thus heat gain inside said structure.

18. A method of using a composite material produced according to claim 8 on the surface of a building to reduce the amount of solar radiation which is converted to thermal energy and thus heat gain inside said building.

19. The method according to claim 8, wherein the carrier material contains minerals, and/or clay, and/or cement, cementitious material, and/or concrete.

20. The method according to claim 8, wherein the carrier material contains polymers.

21. A method of using a composite material produced according to claim 9 on the surface of a closed structure to reduce the amount of incident electromagnetic radiation which is converted to thermal energy and thus heat gain inside said structure.

22. A method of using a composite material produced according to claim 9 on the surface of a building to reduce the amount of incident solar radiation which is converted to thermal energy and thus heat gain inside the building.

23. The method according to claim 9, wherein the carrier material predominantly contains minerals, and/or clay, and/or cement, cementitious material, and/or concrete.

24. The method according to claim 9, wherein the carrier material contains polymers.

25. A method of using a composite material produced according to claim 10 on the surface of a closed structure to reduce the amount of incident electromagnetic radiation which is converted to thermal energy and thus heat gain inside said structure, and to also enhance thermal emittance.

26. A method of using a composite material produced according to claim 12 on the surface of a closed structure to give it a certain visual color and to reduce the amount of solar radiation which is converted to thermal energy and thus heat gain inside said structure.

27. A method of using a composite material produced according to claim 12 on the surface of a building to give it a certain visual color and to reduce the amount of solar radiation which is converted to thermal energy and thus heat gain inside the building.

28. A method of using a composite material produced according claim 14 on the surface of a closed structure to give it a certain visual color, and to reduce the amount of electromagnetic radiation which is converted to thermal energy and thus heat gain inside said structure, and to enhance thermal emittance.

29. A method of using a composite material produced according to claim 14 on the surface of a building to give it a certain visual color, and to reduce the amount of solar radiation which is converted to thermal energy and thus heat gain inside the building, and to enhance thermal emittance and thus thermal energy loss at night.

30. A method of using a composite material produced according to any one of claims 1-3 on the surface of a structure thereby achieving a closer spectral match with the environment at least within the VIS and NIR range.

31. A method of using a composite material produced according to any one of claims 1-3 on the surface of a building or a vehicle thereby achieving a closer spectral match with the environment, and thereby reducing detectability at least within the NIR range.