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

• Current Assignee: Aktieselskabet Aalborg Portland-Cement-Fabrik
• Original Assignee: Aktieselskabet Aalborg Pottland-Cement-Fabrik
• Inventors: Bache, Hans H.
• Primary Examiner(s): BELL, MARK LEE
• Application Number:
  US06/336,380
• Time in Patent Office: 1,595 Days
• Field of Search: 106/90, 106/98, 106/89, 106/97
• US Class Current: 106/644
• CPC Class Codes: B28B 23/0081 Embedding aggregates to obtain particular properties
• CPC Class Codes: C04B 14/00 Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone expanding or defibrillating materials C04B20/00
• CPC Class Codes: C04B 16/00 Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 24/22 Condensation or polymerisation products thereof
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 30/00 Compositions for artificial stone, not containing binders
• CPC Class Codes: C04B 32/02 with reinforcements contains no documents; reinforcing elements E04C5/00
• CPC Class Codes: C04B 40/00 Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02
• CPC Class Codes: C04B 41/45 Coating or impregnating paints C09D, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements ion-implantation C04B41/0027
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Densified systems and articles made therefrom which contain a composite material comprising a coherent matrix of homogeneously arranged inorganic particles (A) of a size of from about 50 Å to about 0.5 3/4, such as silica dust, and densely packed particles (B) having a size of from 0.5-100 μ such as Portland Cement and which are at least one order of magnitude larger than the particles A, and embedded in the matrix, solid particles C made from material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, such as refractory grade bauxite and a surface active dispersing agent. Particles A are homogeneously distributed and especially densely packed, in the void volume between the particles B and are made from an easily flowable composite material containing a very low amount of liquid such as water and an extremely high amount of a dispersing agent such as a concrete superplastisizer. High quality concrete made from a Portland Cement/silica dust matrix with refractory grade bauxite embedded therein exhibits high compressive strength and may be used as a replacement for plastic, glass and steel. High performance fiber/metal matrix composites with substantially improved compressive strength and abrasion resistance are produced.

Claims

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.

2. A shaped article as claimed in claim 1 in which the particles C are densely packed, 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.

3. A shaped article as claimed in claim 1 or 2 in which the particles A are densely packed, or the coherent unitary structure A is formed from such densely packed particles.

4. A shaped article in either of claims 1, 2 or 3 which contains additional bodies D which have at least one dimension which is at least one order of magnitude larger than the particles A, said additional bodies being bodies of a solid, a gas, or a liquid.

5. A shaped article as claimed in claim 4 in which the additional bodies are selected from the group consisting of compact-shaped bodies, plate-shaped bodies, and elongated bodies.

6. A shaped article as claimed in claim 5 in which the additional bodies are selected from the group consisting of sand, stone, polystyrene, expanded clay, hollow glass bodies, expanded shale, natural light weight aggregate, gas bubbles, metal bars, fibers, whiskers, and hydrogen-rich components other than polystyrene.

7. A shaped article according to claim 5 in which the additional bodies D are inherently weak solid bodies of such strength and rigidity that they would be deformed or crushed to a substantial extent under stresses larger than 5 kg/cm² applied to a powder mass consisting of the particles, which particles have retained their geometric identity during the shaping process.

8. A shaped article as claimed in claim 5 in which the additional bodies D are densely packed.

9. A shaped article as claimed in claim 1 in which the particles B are particles which cure by partial dissolution in a liquid, chemical reaction in the dissolved phase, and precipitation of a reaction product.

10. A shaped article as claimed in claim 9 in which the particles A are particles which cure by partial dissolution in a liquid, chemical reaction in the solution, and precipitation of a reaction product.

11. A shaped article as claimed in claim 10 in which the particles A show a substantially lower reactivity than the particles B, or substantially no reactivity.

12. A shaped article as claimed in claim 9 in which the particles B comprise at least 50% by weight of Portland cement particles.

13. A shaped article as claimed in claim 12 in which the particles B comprise particles selected from fine sand, fly ash and fine chalk.

14. A shaped article as claimed in claim 12 in which the particles A are particles of silica dust having a specific surface area of about 50,000-2,000,000 cm² /g.

15. A shaped article according to claim 14 in which the silica dust particles are present in a volume which is about 0.1-50% by volume of the total volume of the particles A+B.

16. A shaped article as claimed in claim 1 in which the particles C consist of materials containing strong natural minerals, strong artificial minerals, and strong metals and alloys, the strength of the particles 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 now 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,

(4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800.

17. A shaped article as claimed in claim 16 in which the particles C consist of one or more of the following components:

topaz, lawsonite, diamond, corundum, phenacite, spinel, beryl, chrysoberyl, tourmaline, granite, andalusite, staurolite, zircon, boron carbide, tungsten carbide, refractory grade bauxite.

18. A shaped article as claimed in claim 17 in which the particles C consist of refractory grade bauxite.

19. A shaped article as claimed claim 1 in which the particles C are present in a volume which is about 10-90% by volume of the total volume of the particles A, B, and C.

20. A shaped article as claimed in claim 1 which contains sand and stone as additional bodies D.

21. A shaped article as claimed in claim 1 which contains fibers as additional bodies D.

22. A shaped article as claimed in claim 21 in which the fibers are selected from the group consisting of metal fibers, mineral fibers, glass fibers, asbestos fibers, high temperature fibers, carbon fibers, and organic fibers.

23. A shaped article as claimed in claim 22 in which the fibers are chopped fibers, or continuous fibers or yarns or ropes, or rovings or staple fibers, or fiber nets or webs.

24. A shaped article as claimed in claim 1 which additionally contains reinforcing steel as bars or rods.

25. A shaped article as claimed in either of claims 23 or 24 in which the bars, rods, or fibers are pre-stressed.

26. An article as claimed in either of claims 23 or 24 in which the additional bodies (fibers, bars, or rods) have retained their geometric identity during the shaping process.

27. An article as claimed in claim 1 which article is a sheet or panel of thin-walled plane or corrugated shape;

a pipe;

a tube;

a refractory lining or a refractory lining component;

a protecting cover;

a roofing material;

an electrically-insulating member;

a nuclear shielding;

a seafloor structure for deep water applications;

a brake lining;

an abrasion aggregate;

a container;

an in situ cast oil well wall;

a load-bearing member in structural engineering;

a machine part;

or a sculpture.

28. An article as claimed in claim 27 in which the matrix thereof is fiber reinforced.

49. An article as claimed in claim 46 in which the material constituting a surface layer is selected from the group consisting of glass;

ceramics;

plastic;

metals;

wood;

paper;

leather;

cement mortar;

concrete;

fiber reinforced cement materials; and

materials with a matrix according to claim 1.

58. A shaped article according to claim 14 in which the silica dust particles have a specific surface area of about 250,000 cm² /g.

59. A shaped article according to claim 15 in which the silica dust particles are present in about 5-50% of the total volume of the particles A+B.

60. A shaped article according to claim 59 in which the silica dust particles are present in about 10-30% of the total volume of the particles A+B.

29. A composite material for producing a shaped article, comprising

(A) inorganic particles of a size of from about 50 Å

to about 0.5μ

,

(B) 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), and

(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, a liquid, and a surface-active dispersing agent,

the amount of particles B substantially corresponding to dense packing thereof in the composite material with homogeneously packed particles A in the voids between particles B, the amount of liquid substantially corresponding to the amount necessary to fill out the voids between particles A and B, and the amount of dispersing agent being sufficient to impart to the composite material a fluid to plastic consistency in a low stress field of less than 5 kg/cm²,

and optionally

(D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles (A),

with the proviso that 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 particles.

31. A composite material as claimed in claim 29 or 30 in which the particles A are present in a volume substantially corresponding to dense packing to fill the voids between the particles B when densely packed, and the surface-active dispersing agent is present in an amount sufficient to allow dense packing of the particles A in a low stress field of less than 5 kg/cm².

32. A composite material as claimed in claim either of the claims 29 or 30 the dispersing agent is present in an amount which substantially corresponds to the amount which will fully occupy the surface of the particles A.

33. A composite material as claimed in either of the claims 29 or 30 in which the particles A are silica dust particles having a specific surface area of about 50,000-2,000,000 cm² /g, the particles B comprise at least 50% by weight of Portland cement, and the dispersing agent is a concrete superplasticiser.

34. A composite material as claimed in either of the claims 29 or 30 in which the particles C are present in a volume substantially corresponding to dense packing between the particles C, 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.

35. A composite material as claimed in claim 33 in which the particles B comprise particles selected from fine sand, fly ash, fine chalk, and fine refractory grade bauxite.

36. A composite material as claimed in claim 33 in which the concrete superplasticiser is an alkali or alkaline earth metal salt of a highly condensed naphthalene sulphonic acid/formaldehyde condensate, of which typically more than 70 percent consist of molecules containing 7 or more naphthalene nuclei.

37. A composite material as claimed in claim 36 in which the alkali or alkaline earth metal salt is a sodium or calcium salt.

38. A composite material as claimed in claim 36 in which the amount of the superplasticiser dry matter is in the range of 1-4, percent, calculated on the total weight of the Portland cement and the silica dust.

39. A composite material as claimed in either of the claims 37 or 38 in which the liquid is water to a weight ratio between water and Portland cement and any other particles B plus silica dust of 0.12 to 0.30.

43. Shaped articles produced from the composite material claimed in either of the claims 29 or 30.

61. A shaped article according to claim 33 in which the silica dust particles have a specific surface area of about 250,000 cm² /g.

30. A composite material for producing a shaped article, comprising

(A) inorganic particles of a size of from about 50 Å

to about 0.5μ

,

(B) 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),

(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 a surface-active dispersing agent,

the amount of particles B substantially corresponding to dense packing thereof in the composite material with homogeneously packed particles A in the voids between particles B, and the amount of dispersing agent being sufficient to impart to the composite material a fluid to plastic consistency in a low stress field of less than 5 kg/cm², when an amount of liquid substantially corresponding to the amount necessary to fill out the voids between particles A and B has been added,

and optionally

(D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles (A),

with the proviso that 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 particles.

40. A composite material as claimed in either of claims 30 or 31 in which the particles C consist of materials containing strong natural minerals, strong artificial minerals, and strong metals and alloys, the strength of the particles corresponding to

(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,

(4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800.

41. A composite material as claimed in claim 40 in which the particles C consist of one or more of the following components:

topaz, lawsonite, diamond, corundum, phenacite, spinel, beryl, chrysoberyl, tourmaline, granite, andalusite, staurolite, zircon, boron carbide, tungsten carbide, refractory grade bauxite.

42. A composite material as claimed in claim 41 in which the particles C consist of refractory grade bauxite.

44. A process for preparing a shaped article 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;

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;

containers;

machine parts; and

sculptures;

comprising combining

(A) inorganic solids particles of a size of from about 50 Å

to about 0.5μ

, and

(B) 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),

(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 100 μ

-0.1 m, a liquid, and a surface-active dispersing agent,

the amount of particles B substantially corresponding to dense packing thereof in the composite material with homogeneously packed particles A in the voids between particles B, the amount of liquid substantially corresponding to the amount necessary to fill out the voids between particles A and B, and the amount of dispersing agent being sufficient to impart to the composite material a fluid to plastic consistency in a low stress field of less than 5 kg/cm²,

and optionally

(D) additional bodies which have at least one dimension which is one order of magnitude larger than the particles A,

by mechanically mixing the particles A, the liquid, and the surface active dispersing agent, optionally together with particles B, particles C and/or additional bodies D until a viscous to plastic mass has been obtained,

and therefter, if necessary or if desired, respectively, combining the resulting mass with particles and/or bodies of the type mentioned above (B, C, D) by mechanical means to obtain the desired distribution of the components and finally casting the resulting mass in the desired shape in a stress field optionally with incorporation of particles C and/or additional bodies D during the casting.

45. A shaped article comprising a matrix which comprises a Portland cement-based binder and compact-shaped solid particles having a size of 100μ

-0.1 m embedded in the matrix, the article having a compressive strength of

more than 150 MPa measured on a test specimen having a diameter of 10 cm and a height of 20 cm, when the largest of the compact-shaped bodies is larger than 4 mm, and

more than 180 MPa, measured on a test specimen having a diameter of 3 cm and a height of 6 cm, when the largest of the compact-shaped bodies is at most 4 mm,

with the proviso that the shaped article has at least one dimension which is at least one meter and a cross section of at least 0.1 m², and/or has a complex shape which does not permit its establishment by powder compaction.

46. 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 optionally

(D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles A,

the article additionally comprising a surface layer or surface layers which has (have) a substantially uniform thickness and a structure which is different from the above-defined structure adjacent to the surface layer or layers.

47. An article as claimed in claim 46 which comprises the structure constituted by the particles A, B and optionally the additional bodies D is arranged between surface layers which have a substantially uniform thickness and which are of a material different from the matrix constituted by the particles A and B.

48. An article as claimed in claim 46 or 47 in which the structure covered by surface or surfaces comprises 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 additionally comprises, 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.

50. An article as claimed in either of the claims 46 or 49 which is an electrical insulating member, a piece of furniture, a bookshelf, a door, a strongbox or a part thereof, a container for radioactive material, a sculpture, a load-bearing member, a ship hull, a tube or line, or a chimney.

51. A shaped article comprising a coherent matrix,

the matrix comprising

(A) homogeneously arranged bodies 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 bodies 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 bodies A or the coherent structure formed therefrom being homogeneously distributed in the void volume between the bodies 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,

the shaped article optionally 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 above 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,

the bodies A and B being bodies of a gas, a liquid, or a solid.

52. A shaped article comprising a matrix comprising fibers having a transverse dimension of less than 100 μ

m and bodies or particles of a size of from about 50 Å

to about 0.5 μ

m homogeneously arranged and substantially densely packed in the voids between the fibers, the fiber volume percentage of the matrix being at least 30%.

53. A shaped article according to claim 52 wherein the fiber volume is at least 40%.

54. A shaped article according to claim 52 or 53 wherein the inter-particle substance is a metal or plastics material.

55. A cast which consists of a material 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 lrger 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 optionally 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 above 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.

56. A coating composition comprising a material 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 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 above 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.

57. A coating composition according to claim 56 in which the matrix comprises components improving the attachment of the coating to the substrate on which the coating is applied, said components comprising long and or tangled molecules of high molecular weight selected from the group consisting of ionic polymers, silica in polymeric form, polycarboxylates and chains of dentin collagen.