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Shaped article and composite material and method for producing same

  • US 4,588,443 A
  • Filed: 12/30/1981
  • Issued: 05/13/1986
  • Est. Priority Date: 05/01/1980
  • Status: Expired due to Term
First Claim
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1. A shaped article comprising a coherent matrix, the matrix comprising(A) homogeneously arranged inorganic solid particles of a size of from about 50 Å

  • to about 0.5μ

    , or a coherent structure formed from such homogeneously arranged particles, and(B) densely packed solid particles having a size of the order of 0.5-100μ and

    being at least one order of magnitude larger than the respective particles stated under (A), or a coherent structure formed from such densely packed particles,the particles A or the coherent structure formed therefrom being homogeneously distributed in the void volume between the particles B,the dense packing being substantially a packing corresponding to the one obtainable by gentle mechanical influence on a system of geometrically equally shaped large particles in which locking surface forces do not have any significant effect,and a surface active dispersing agent effective to secure the homogeneous distribution of particles A and being present in an amount sufficient to secure the homogeneous distribution of particles A, the shaped article additionally comprising embedded in the matrix,(C) compact-shaped solid particles of a material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, typically a strength corresponding to at least one of the following criteria;

    (1) a die pressure of about 30 MPa at a degree of packing of 0.70, above 50 MPa at a degree of packing of 0.75, and above 90 MPa at a degree of packing of 0.80, (on particles of the material having a size ratio between the largest and smallest particle substantially not exceeding 4 mm),(2) a compressive strength of a composite material with the particles embedded in a specified matrix exceeding 170 MPa (in case of a substantial amount of the particles being larger than 4 mm) and 200 MPa (in case of substantially all particles being smaller than 4 mm),(3) a Moh'"'"'s hardness (referring to the mineral constituting the particles) exceeding 7 and(4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800, said particles having a size of 100μ

    -0.1 m, and optionally(D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles A,whereby, when the shaped article is not selected from the group consisting of in situ cast oil well walls;

    duct fillings;

    fissure fillings;

    sheets;

    panels and tiles of thin-walled plane or corrugated shape;

    anti-corrosion protecting covers applied on steel and concrete members;

    pipes;

    tubes;

    electrically insulating members;

    nuclear shieldings;

    seafloor structures for deep water application;

    brake linings;

    abrasion aggregates;

    machine parts;

    sculptures; and

    containers;

    the following provisos apply;

    (1) when additional bodies D are not present or are present and consist of sand and/or stone, at least 20% by weight of the particles B are Portland cement, and further(2) when the particles B do not have a molecular structure different from the molecular structure of the particles A, the shaped article is selected from the group consisting of articles produced by shaping in a low stress field of less than 5 kg/cm2, preferably less than 100 g/cm2, articles having at least one dimension of at least one meter and having a minimum cross section of at least 0.1 m2, and articles having a complex shape that does not permit its establishment by powder compaction.

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