Inorganic matrix compositions and composites incorporating the matrix composition

• US 20050022698A1
• Filed: 08/30/2004
• Published: 02/03/2005
• Est. Priority Date: 09/20/2000
• Status: Active Grant

• Current Assignee: Goodrich Corporation (Rtx Corporation)
• Original Assignee: Goodrich Corporation (Rtx Corporation)
• Inventors: Robinson, John W., Mazany, Anthony M., Cartwright, Craig J.
• Granted Patent: US 7,732,358 B2
• Time in Patent Office: Days
• US Class Current: 106/600
• CPC Class Codes: C03C 1/006 to produce glass through wet route
• CPC Class Codes: C03C 25/42 Coatings containing inorganic materials
• CPC Class Codes: C03C 3/064 containing boron
• CPC Class Codes: C03C 3/19 containing boron
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/30 Oxides other than silica ferrites C04B14/363
• CPC Class Codes: C04B 14/304 Magnesia
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2111/00112 Mixtures characterised by specific pH values
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/12 Nitrogen containing compounds organic derivatives of hydrazine hydrazine C04B22/00
• CPC Class Codes: C04B 28/006 containing mineral polymers, e.g. geopolymers of the Davidovits type
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: C04B 40/024 Steam hardening, e.g. in an autoclave
• CPC Class Codes: C04B 40/0259 Hardening promoted by a rise in pressure C04B40/024 takes precedence
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: Y02P 40/10 : Production of cement, e.g. improving or optimising the production methods; Cement grinding

Abstract

A modified alkali silicate composition for forming an inorganic network matrix. 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 inorganic composition, such as a reactive glass, water and optional fillers, additives and 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 applying the temperature and pressure necessary to consolidate the desired form. The composite can be shaped by compression molding as well as other known fabrication methods. A notable aspect of the invention is that, although composite and neat resin components prepared from the invention can exhibit excellent dimensional stability to 1000° C. and higher, they can be prepared at the lower temperatures and pressures typical to organic polymer processing.

Claims

1. A glass comprising:

an acidic composition having the formula;

${\underset{k=1}{\overset{n}{\prod <br><br>}}<br><br>\text{\hspace{1em}<br><br>}<br><br>\left({\left(M^{p+}\right)}_{q^{\mathrm{\prime <br><br>}}}\right)<br><br>{\left(E^{q-}\right)}_{p^{\mathrm{\prime <br><br>}}})}_{r_k}<br><br>\mathrm{where}<br><br>\text{\hspace{1em}<br><br>}<br><br>\sum <br><br>r_k=1$

where M is at least one glass former and at least one metallic glass modifier, E is an oxygen, chalcogenide and/or a halogen atom, p is the cation valence of M, q is the anion valence of E, q′

is number of M cations contained in a network unit, p′

is number of E anions contained in a network unit, r is the molar fraction of that network unit, and n is the number of network units or building blocks and ranges from about 2 to about 30.

2. The glass of claim 1, wherein the glass former is boron, silicon, phosphorus, sulfur, germanium, arsenic, or antimony, or combinations thereof;

wherein the metallic glass modifier is at least one composition which functions as a flux, and includes lithium, sodium, potassium, rubidium, or cesium, or combinations thereof; and

, optionally, a network modifier comprising vanadium, aluminum, titanium, chromium, manganese, iron, cobalt, nickel, copper, mercury, zinc, thulium, lead, zirconium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, actinium, thorium, uranium, yttrium, gallium, magnesium, calcium, strontium, barium, tin, bismuth, or cadmium, or combinations thereof.

3. The glass of claim 1, wherein E is oxygen, chalcogenides, or fluorine, or mixtures thereof.

4. The glass of claim 1, wherein the glass former is boron, silicon, phophorus, or sulfur, or combinations thereof;

wherein the glass network modifier is vanadium, tin, titanium, zinc, lead, aluminum, zirconium, lanthanum, cerium, neodymium, magnesium, calcium, strontium, barium, lithium, sodium, or potassium, or combinations thereof; and

E is an oxygen atom.

5. A glass comprising the following formula:

a(A′

₂O)_xb(G_fO)_yc(A″

O)_z

where A′

represents at least one alkali metal glass modifiers, which function as a fluxing agent, G_f represents at least one glass former comprising boron, A″

represents, optionally, at least one glass network modifier, a represents the number of fluxing agents present and ranges from about 1 to about 5, b represents the number of glass formers present and ranges from about 1 to about 10, c represents the number of glass network modifiers and ranges from 0 or about 0.1 to about 30, x represents the mole fraction of fluxing agent and is from about 0.050 to about 0.500, y represents the mole fraction of glass former and is from about 0.040 to about 0.950 with the proviso that the amount of boron as B₂O₃ is at least about 0.040, z represents the mole fraction of glass network modifiers and is from about 0.000 or about 0.001 to about 0.600, x+y+z=1, and x<

y, and wherein said glass is acidic.

6. The composition of claim 5, wherein A′

is lithium, sodium, potassium, rubidium, or cesium, or combinations thereof.

7. The glass of claim 6, wherein G_f is boron, silicon, phosphorus, sulfur, germanium, arsenic, antimony, or combinations thereof.

8. The glass of claim 7, wherein A″

O is vanadium oxide, titanium oxide, zinc oxide, lead oxide, aluminum oxide, zirconium oxide, lanthanum oxide, cerium oxide, neodymium oxide, magnesium oxide, calcium oxide, strontium oxide, barium oxide, or silicone oxide, or combinations thereof.

9. The glass of claim 5, wherein A″

O is at least one glass network modifier.

10. The glass of claim 8, wherein A″

O is at least two glass network modifiers.

11. The glass of claim 5 wherein a is 1, b is 2, and c is 1.

12. The glass of claim 5, wherein a is 1, b is 2, and c is 2, and A′

is Li, G_fO is P₂O₅ and B₂O₃, and A″

O is MgO and BaO.

13. The glass of claim 5, wherein the reactive glass composition comprises the following formula:

(Li₂O)_x(P₂O₅)_y1(B₂O₃)_y2c(A″

O)_z,

wherein A″

O is at least one glass network modifier, c is from about 1 to about 30, x is from about 0.050 to about 0.500, y₁ is from about 0.030 to about 0.950, y₂ is from about 0.010 to about 0.150, z is from about 0.010 to about 0.300, and x+y₁+y₂+z=1.

14. The composition of claim 13, wherein A″

O is magnesium oxide, barium oxide, zinc oxide, silicon oxide, or aluminum oxide, or combinations thereof.

15. The glass of claim 5, wherein the reactive glass composition comprises the following formula

(LiO)_x(P₂O₅)_y1(B₂O₃)_y2MgO)_z1(BaO)_z2(Al₂O₃)_z3

where x ranges from about 0.050 to about 0.500, y₁ ranges from about 0.030 to about 0.800, y₂ ranges from about 0.010 to about 0.700, z₁ ranges from about 0.010 to about 0.200, z₂ ranges from about 0.010 to about 0.200, and z₃ ranges from about 0.010 to about 0.200, x+y₁+y₂+z₁+z₂+z₃=1 and x<

y₁+y₂.

16. The glass of claim 5, wherein the reactive glass composition comprises the following formula

(LiO)_x(P₂O₅)_y1(B₂O₃)_y2(SiO₂)_y3MgO)_z1(BaO)_z2(Al₂O₃)_z3

where x ranges from about 0.050 to about 0.500, y₁ ranges from about 0.030 to about 0.800, y₂ ranges from about 0.010 to about 0.700, y₃ ranges from about 0.010 to about 0.200, z₁ ranges from about 0.010 to about 0.200, z₂ ranges from about 0.010 to about 0.200, and z₃ ranges from about 0.010 to about 0.200, x+y₁+y₂+y₃+z₁+z₂+z₃=1 and x<

y₁+y₂+y₃.

17. The glass of claim 5, wherein said glass has a pH of less than 7.0.

18. The glass of claim 8, wherein the glass has a pH of from about 1 to about 5.0.

19. The glass of claim 14, wherein the glass has a pH of from about 1 to about 5.0.

20. The glass of claim 16, wherein the glass has a pH of from about 1 to about 5.0.