Self-repairing, reinforced matrix materials

• US 7,022,179 B1
• Filed: 02/28/2003
• Issued: 04/04/2006
• Est. Priority Date: 06/19/1990
• Status: Expired due to Fees

• Current Assignee: Carolyn M. Dry
• Original Assignee: Carolyn M. Dry
• Inventors: Dry, Carolyn M.
• Primary Examiner(s): MARCHESCHI, MICHAEL A
• Application Number:
  US10/376,906
• Time in Patent Office: 1,131 Days
• Field of Search: 106/677, 106/711, 106/724, 106/729, 106/823, 106/802, 106/805, 106/676, 106/819, 501/95.1, 753/00, 523/218, 523/219, 428/320.2, 428/321.1, 428/321.5, 428/364
• US Class Current: 106/711
• CPC Class Codes: A61L 27/48 with macromolecular fillers
• CPC Class Codes: A61L 27/50 Materials characterised by their function or physical properties , e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/10 Coating or impregnating roofing granules E04D7/005
• CPC Class Codes: C04B 2103/00 Function or property of ingredients for mortars, concrete or artificial stone
• CPC Class Codes: C04B 26/02 Macromolecular compounds
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0675 Mortars activated by rain, percolating or sucked-up water; Self-healing mortars or concrete
• CPC Class Codes: C08J 5/00 Manufacture of articles or shaped materials containing macromolecular substances manufacture of semi-permeable membranes B01D67/00 - B01D71/00
• CPC Class Codes: Y10T 428/249994 Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]
• CPC Class Codes: Y10T 428/249995 Constituent is in liquid form
• CPC Class Codes: Y10T 428/249997 Encapsulated liquid
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber

Abstract

Self-repairing, fiber reinforced matrix materials include a matrix material including inorganic as well as organic matrices. Disposed within the matrix are hollow fibers having a selectively releasable modifying agent contained therein. The hollow fibers may be inorganic or organic and of any desired length, wall thickness or cross-sectional configuration. The modifying agent is selected from materials capable of beneficially modifying the matrix fiber composite after curing. The modifying agents are selectively released into the surrounding matrix in use in response to a predetermined stimulus be it internal or externally applied. The hollow fibers may be closed off or even coated to provide a way to keep the modifying agent in the fibers until the appropriate time for selective release occurs. Self-repair, smart fiber matrix composite materials capable of repairing microcracks, releasing corrosion inhibitors or permeability modifiers are described as preferred embodiments in concrete and polymer based shaped articles.

Claims

1. A shaped article of composite material, comprising:

a cured polymer matrix, and

a plurality of hollow release vessels, wherein at least one of a polymerizer and a catalyst is situated in the release vessels, and wherein at least one of the polymerizer and the catalyst is selectively releasable from the release vessels in response to a predetermined external stimulus to modify a performance characteristic of the cured matrix material.

2. The article of claim 1, wherein only a portion of said polymerizer is released upon an initial stimulus occurrence in order to permit at least one subsequent release of said polymerize upon a subsequent stimulus occurrence.

3. The article of claim 1, wherein only a portion of said catalyst is released upon an initial stimulus occurrence to permit at least one subsequent release of said catalyst upon a subsequent stimulus occurrence.

4. The article of claim 1, wherein the polymer is selected from the group consisting of thermoplastic polymers, thermosetting polymers, thermoplastic elastomers, crosslinkable polymers, and curable polymer resin systems.

5. The article of claim 1, wherein the polymer is selected from the group consisting of polyolefins, polyesters, polycarbonates, polyacrylates, polyarylayes, polyamides, polyimides, polyaramides, polyurethanes, and foaming polyurethanes.

6. The article of claim 1 wherein the polymer is selected from the group consisting of one and two part epoxies and phenolformaldehyde resins.

7. The article of claim 1 wherein the polymer is selected from the group consisting of styrene-butadiene, rubber, neoprene, SEBS, NBR, EPDM rubber, latex, and viscoelastic materials.

8. The article of claim 1 wherein at least one of the polymerizer and catalyst is a modifying agent.

9. The article of claim 8 wherein the modifying agent is a polymerizable material.

10. The article of claim 9 wherein the modifying agent is a monomer.

11. The article of claim 10, wherein the monomer is selected from the group consisting of methylmethacrylate and styrene.

12. The article of claim 8 wherein the modifying agent is a two part epoxy having components selected from the group consisting of epoxy precursors, amines, and cross-linking agents.

13. The article of claim 8 wherein the modifying agent is an adhesive.

14. The article of claim 13 wherein the adhesive is selected from the group consisting of one and two part epoxies and cyanoacrylates.

15. The article of claim 8 wherein the modifying agent is a curable monomer.

16. The article of claim 8 wherein the modifying agent is a co-monomer.

17. The article of claim 8 wherein the modifying agent is selected from the group consisting of acidic, alkaline or viscoelastic materials.

18. A shaped article of a self-repairing composite material, comprising a matrix comprising a cured polymer, a plurality of hollow release vessels in the matrix, and at least one of a polymerizer and a catalyst in the release vessels, wherein the polymerizer and the catalyst are selected from a modifying agent capable of modifying the composite material.

19. The article of claim 18 wherein the modifying agent is a polymerizer.

20. The article of claim 18 wherein the modifying agent is two part epoxy, and wherein the matrix is a two part epoxy matrix.

21. The article of claim 18 wherein the modifying agent is a crosslinking material, and wherein the matrix is a crosslinked polymer matrix.

22. A shaped article of composite material comprising a cured matrix, at least one hollow release vessel, and a modifying agent, wherein the modifying agent is chemically compatible with the matrix and is capable of beneficially modifying the composite material in response to a predetermined external stimulus.

23. The article of claim 22 wherein at least one of the matrix and the modifying agent are a polymer.

24. The article of claim 23, wherein the matrix and modifying agent are selected from the group consisting of thermoplastic polymers, thermosetting polymers, thermoplastic elastomers, crosslinkable polymers, and curable polymer resins.

25. The article of claim 23, wherein the matrix and the modifying agent are polymers selected from the group consisting of polyolefins, polyesters, polycarbonates, polyacrylates, polyarylayes, polyamides, polyimides, polyaramides, polyurethanes, and foaming poyurethanes.

26. The article of claim 23, wherein the matrix and the modifying agent are thermosetting, cross-linkable and curable resins.

27. The article of claim 26 wherein the thermosetting, cross-likable and curable resins are selected from the group consisting of one part epoxies, two part epoxies, and phenolformaldehyde resins.

28. The article of claim 23, wherein the matrix and the modifying agent are selected from the group consisting of styrene-butadiene, rubber, neoprene, SEBS, NBR, EPDM rubber, latex, and viscoelastic materials.

29. The article of claim 23, wherein the matrix and the modifying agent are selected from the group consisting of aromatic and olefin materials.

30. The article of claim 22 wherein the matrix and the modifying agent are metal.

31. The article of claim 22 wherein the matrix and the modifying agent are cementitous.

32. The article of claim 23, wherein the modifying agent is a metal.

33. The article of claim 23, further comprising a coating on the release vessels.

34. The article of claim 33, wherein the release vessel is a particle.

35. The article of claim 22 wherein the release vessels are particles.

36. The article as in claim 22 wherein the plurality of release vessels contain a plurality of different modifying agents.

37. The article of claim 22 wherein the release vessels are fibers or particles selected from the group consisting of polyolefin, polyester, polyamide, polyaramid, polyimide, carbon, graphite, cellulose, nitrocellulose, hydrocarbons, polytetrafluoroethylene, aramids, polpropylene, and elastomers.