Inorganic matrix compositions, composites incorporating the matrix, and process of making the same
First Claim
1. The inorganic polymer matrix comprising a reaction product of an alkali silicate, one or more non-silicate network formers and/or reactive glass, water and optionally one or more additives, and one or more network modifiers.
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Abstract
A modified alkali silicate composition for forming an inorganic polymer matrix having improved mechanical properties. The modified alkali silicate matrix is made by reacting an alkali silicate (or its precursors such as an alkali hydroxide, a SiO2 source and water), a non-silicate network former and/or reactive glass, water and optionally one or more multivalent cation(s) selected from Groups 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 or 16 of the periodic table such as an alkaline earth salt, water and optional processing aids. An inorganic matrix composite can be prepared by applying a slurry of the modified aqueous alkali silicate composition to a reinforcing medium and curing the composite at a temperature from about 15° C. up to 1000° C. and a pressure of up to 20,000 psi for typical high-performance organic polymer processing (temperatures about 15° C. to about 200° C. and pressures <200 psi). The composite can be shaped by compression molding as well as other known fabrication methods.
85 Citations
105 Claims
- 1. The inorganic polymer matrix comprising a reaction product of an alkali silicate, one or more non-silicate network formers and/or reactive glass, water and optionally one or more additives, and one or more network modifiers.
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2. The inorganic polymer matrix comprising the reaction product of an alkali base, a silica source, water, one or more non-silicate network formers and/or reactive glass, one or more network modifiers and optionally, one or more fillers.
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28. A matrix composition comprising:
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(1−
n)(aA2O;
SiO2;
bB;
cC;
dDx)·
nH2Owherein;
A=(1−
z) K2O or (z)Na2O, where z can vary between 0 and 1, K2O is potassium oxide, and Na2O is sodium oxide;
Li2O can be added if desired.SiO2 is silica or a combination of various silicas;
H2O is water;
a=molar ratio of A2O;
SiO2, which ranges from 0.05 to 1.0,b=molar ratio of B;
SiO2, which ranges from 0.001 to 0.500,c=molar ratio of C;
SiO2, which ranges from 0.0 to 0.250,d=is the molar ratio of D;
SiO2 and ranges from 0.0 to 2.000,n=molar ratio of H2O incorporated into the formulation, for which during initial formulation which ranges from 0.10 to 0.90, x=the number of additives (D) used to aid in processing and performance of the basic formulation and ranges from 0 to 20, B=non-silicate network formers, or a reactive glass, or combination thereof, C=network modifiers such as Mg2+, Ca2+, Zn2+, Al3+, Ti4+ derived from multivalent main group metal and/or transition metal compounds such as Mg(NO3)2, ZnCl2, or a combination thereof or as a metallic component of a reactive glass, and D=optional additives selected from one or more, alone or in combination, of (i) reactive fillers or nonreactive fillers or combinations thereof;
(ii) gelation modifiers;
(iii) a surface-active agents selected from an anionic, cationic or nonionic surfactants or combinations thereof; and
(iv) organic-based toughening agents or plasticizing agents or combinations thereof. - View Dependent Claims (29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 47, 48, 49, 50, 51, 52, 53, 54)
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- 55. An inorganic polymer matrix composition comprising a polymer matrix and reinforcement having enhanced level of mechanical strength where the reinforcement exhibits an oxophilic character at the interface formed between the polymer matrix and reinforcement.
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56. An inorganic polymer matrix composition comprising a polymer matrix and graphite and carbon reinforcement having enhanced level of mechanical strength due to an improved interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by chemical oxidation.
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57. An inorganic polymer matrix composition comprising a polymer matrix and graphite and carbon reinforcement having enhanced level of mechanical strength due to the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by thermal oxidation.
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58. An inorganic polymer matrix composition comprising a polymer matrix and graphite or carbon reinforcement having enhanced level of mechanical strength due to an improved interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by chemical oxidation.
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59. An inorganic polymer matrix composition comprising a polymer matrix and graphite or carbon reinforcement having enhanced level of mechanical strength due to the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by thermal oxidation.
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60. An inorganic polymer matrix composition comprising a polymer matrix and reinforcement having enhanced level of mechanical strength due to the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by metallization.
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61. An inorganic polymer matrix composition comprising a polymer matrix and graphite and carbon reinforcement having enhanced level of mechanical strength due to the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by electrolytic oxidation.
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62. An inorganic polymer matrix composition comprising a polymer matrix and graphite or carbon reinforcement having enhanced level of mechanical strength due to the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by electrolytic oxidation.
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63. An inorganic polymer matrix composition comprising a polymer matrix and a reinforcement having improved interfacial strength.
- 71. An inorganic polymer matrix composition comprising a polymer matrix and a reinforcement having an enhanced level of mechanical strength due to the interface formed between the polymer matrix and the reinforcement, wherein said reinforcement has an irregular or roughened surface or a combination thereof.
- 72. An inorganic polymer matrix composition comprising an alkali silicate, and a reactive glass.
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76. An inorganic polymer matrix composition comprising an alkali silicate and potassium dihydrogen phosphate.
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77. A reinforced inorganic polymer matrix composition comprising a reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface formed between the polymer matrix and reinforcement.
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78. A reinforced inorganic polymer matrix composition comprising a reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by metallization.
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79. A reinforced inorganic polymer matrix composition comprising carbon or graphite reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by chemical oxidation.
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80. A reinforced inorganic polymer matrix composition comprising carbon or graphite reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by thermal oxidation.
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81. A reinforced inorganic polymer matrix composition comprising carbon or graphite reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface formed between the polymer matrix and reinforcement, wherein said reinforcement is treated by electrolytic oxidation.
- 82. A reinforced inorganic polymer matrix composition comprising a reinforcement and an alkali silicate, wherein the reinforcement exhibits an oxophilic character at the interface between the matrix and the reinforcement as a result of the application of sizing to the reinforcement.
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90. A reinforced inorganic polymer matrix composition comprising a reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface between the matrix and the reinforcement as a result of a sizing comprising polyvinyl alcohol being applied to the reinforcement.
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91. A reinforced inorganic polymer matrix composition comprising a reinforcement and an alkali silicate and wherein the reinforcement exhibits an oxophilic character at the interface between the matrix and the reinforcement as a result of a primer comprising polyvinyl alcohol being applied to the reinforcement.
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92. A reinforced inorganic polymer matrix composition comprising a reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface between the matrix and the reinforcement as a result of polyvinyl alcohol being applied to the composition.
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93. A reinforced inorganic polymer matrix composition comprising reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface between the matrix and the reinforcement as a result of a sizing comprising crosslinked polyvinyl alcohol being applied to the reinforcement.
- 94. A reinforced inorganic polymer matrix composition comprising a reinforcement and an alkali silicate wherein the reinforcement exhibits an oxophilic character at the interface between the matrix and the reinforcement as a result of a primer comprising crosslinked polyvinyl alcohol being applied to the reinforcement.
- 95. A reinforced inorganic polymer matrix composition containing a reinforcement comprising a reaction product of an alkali silicate and a phosphoborate glass, wherein the reinforcement exhibits an oxophilic character at the interface between the matrix and reinforcement.
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96. A glass composition comprising about 10 mol % to about 50 mol % of phosphorus pentoxide or its salts, acids or precursor forms;
- about 10 mol % to about 70 mol % of boron oxide;
about 5 mol % to about 45 mol % of an alkali oxide and from about 0 mol % to about 30 mol % of an alkaline earth oxide. - View Dependent Claims (101, 102)
- about 10 mol % to about 70 mol % of boron oxide;
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97. A glass composition comprising about 20 mol % to about 40 mol % of phosphorus pentoxide or its salts, acids or precursor forms;
- about 30 mol % to about 60 mol % of boron oxide;
about 20 mol % to about 40 mol % of an alkali oxide and from about 5 mol % to about 20 mol % of an alkaline earth oxide. - View Dependent Claims (103)
- about 30 mol % to about 60 mol % of boron oxide;
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98. A glass composition comprising about 25 mol % to about 35 mol % of phosphorus pentoxide or its salts, acids or precursor forms;
- about 45 mol % to about 55 mol % of boron oxide;
about 15 mol % to about 30 mol % of an alkali oxide and from about 10 mol % to about 15 mol % of an alkaline earth oxide. - View Dependent Claims (104)
- about 45 mol % to about 55 mol % of boron oxide;
Specification