Inorganic matrix compositions and composites incorporating the matrix composition
First Claim
1. A method of making an inorganic silicate composite comprising the steps of:
- applying an aqueous slurry comprising a mixture of an alkali silicate, a reactive acidic glass, water, and, optionally a clay, or optionally an oxide filler, to a reinforcing media comprising fibers, fabrics, or microspheres, and curing the composite by applying heat at a temperature of about 15°
C. up to about 1000°
C. and a pressure range from a vacuum from about ambient to about 10−
3 torr, and/or external pressure from about ambient to about 20,000 psi.
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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.
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Citations
17 Claims
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1. A method of making an inorganic silicate composite comprising the steps of:
- applying an aqueous slurry comprising a mixture of an alkali silicate, a reactive acidic glass, water, and, optionally a clay, or optionally an oxide filler, to a reinforcing media comprising fibers, fabrics, or microspheres, and curing the composite by applying heat at a temperature of about 15°
C. up to about 1000°
C. and a pressure range from a vacuum from about ambient to about 10−
3 torr, and/or external pressure from about ambient to about 20,000 psi. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 15, 17)
- applying an aqueous slurry comprising a mixture of an alkali silicate, a reactive acidic glass, water, and, optionally a clay, or optionally an oxide filler, to a reinforcing media comprising fibers, fabrics, or microspheres, and curing the composite by applying heat at a temperature of about 15°
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9. A method of making an inorganic silicate composite comprising the steps of applying an aqueous slurry comprising a mixture of an alkali silicate, a reactive acidic glass, water and optionally a modifier that moderates the gelation of a matrix binder suspension, optionally a clay, or optionally an oxide filler, to a reinforcing media comprising fibers, fabrics, or microspheres, and curing the composite by applying heat at a temperature of about 15°
- C. up to about 1000°
C. and pressures under vacuum from ambient to about 10−
3 torr, and/or external pressure from ambient to about 20,000 psi. - View Dependent Claims (10, 11, 12, 13, 14, 16)
- C. up to about 1000°
Specification