Inorganic matrix compositions, composites and process of making the same
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Abstract
A modified alkali silicate composition for forming an inorganic network. 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), an acidic oxoanionic compound such as phosphoric acid, 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.
45 Citations
54 Claims
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1-31. -31. (Cancelled)
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32. A method of making an inorganic silicate composite comprising the steps of:
- applying an aqueous slurry of a mixture of an alkali silicate, an oxoanionic compound, a clay filler, an alkaline earth salt and water to a reinforcing medium and curing the composite by applying heat at a temperature of about 15°
C. up to about 1000°
C.+, an external pressure from ambient to about 20,000 psi, and optionally under a vacuum of about ambient to about 10−
3 torr. - View Dependent Claims (33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 53, 54)
- applying an aqueous slurry of a mixture of an alkali silicate, an oxoanionic compound, a clay filler, an alkaline earth salt and water to a reinforcing medium and curing the composite by applying heat at a temperature of about 15°
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45-51. -51. (Cancelled)
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52. A method of making an inorganic silicate composite comprising the steps of:
- applying an aqueous slurry of a mixture of an alkali silicate, phosphoric acid, water and optionally a clay filler, an alkaline earth salt and/or a gel modifier to a reinforcing medium and curing the composite by applying heat at a temperature of about 15°
C. up to about 1000°
C. and external pressures from ambient pressure to about 20,000 psi and/or under a vacuum of from about ambient to about 10−
3 torr.
- applying an aqueous slurry of a mixture of an alkali silicate, phosphoric acid, water and optionally a clay filler, an alkaline earth salt and/or a gel modifier to a reinforcing medium and curing the composite by applying heat at a temperature of about 15°
Specification