High dielectric constant composite materials and methods of manufacture
First Claim
1. A composite material having a high dielectric constant and high dielectric strength, the composite material comprising:
- a quadmodal distribution of high dielectric constant ceramic particles bonded together by a polymeric material, wherein the quadmodal distribution comprises at least one first ceramic particle having a first diameter in a first range between 40 μ
m and 220 μ
m, at least one second ceramic particle having a second diameter in a second range between 500 nm and 5 μ
m, and at least one third ceramic particle having a third diameter in a third range between 2 nm and 500 nm; and
,wherein the polymeric material is polymerized in-situ from a polymeric precursor and binds directly to a surface of each of the high dielectric constant ceramic particles.
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Abstract
The present invention relates to composite materials with a high dielectric constant and high dielectric strength and to methods of producing the composite materials. The composite materials have high dielectric constants at a range of high frequencies and possess robust mechanical properties and strengths, such that they may be machined to a variety of configurations. The composite materials also have high dielectric strengths for operation in high power and high energy density systems. In one embodiment, the composite material is composed of a trimodal distribution of ceramic particles, including barium titanate, barium strontium titanate (BST), or combinations thereof and a polymer binder.
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Citations
80 Claims
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1. A composite material having a high dielectric constant and high dielectric strength, the composite material comprising:
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a quadmodal distribution of high dielectric constant ceramic particles bonded together by a polymeric material, wherein the quadmodal distribution comprises at least one first ceramic particle having a first diameter in a first range between 40 μ
m and 220 μ
m, at least one second ceramic particle having a second diameter in a second range between 500 nm and 5 μ
m, and at least one third ceramic particle having a third diameter in a third range between 2 nm and 500 nm; and
,wherein the polymeric material is polymerized in-situ from a polymeric precursor and binds directly to a surface of each of the high dielectric constant ceramic particles. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A composite material having a high dielectric constant and high dielectric strength, the composite material comprising:
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a trimodal distribution of high dielectric constant ceramic particles bonded together by a polymeric material, wherein the trimodal distribution comprises at least one first ceramic particle having a first diameter in a first range between 40 μ
m and 220 μ
m, at least one second ceramic particle having a second diameter in a second range between 500 nm and 5 μ
m, and at least one third ceramic particle having a third diameter in a third range between 2 nm and 500 nm; and
,the polymeric material is a gelling polymer, wherein the polymeric material is mixed with a solvent and the polymeric material absorbs at least a portion of the solvent to form a gel. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17)
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18. A method for manufacturing a composite material having a high dielectric constant and high dielectric strength, the composite material including a quadmodal distribution of high dielectric constant ceramic particles and a polymeric material, where the polymeric material is mixed with the distribution of high dielectric constant ceramic particles and a polymer is formed in situ;
- the method comprising;
mixing a ceramic powder distribution with a liquid polymer precursor into a paste; placing the paste into a die; compressing the paste; and
,polymerizing the polymer precursor to form a polymer that binds directly to ceramic particles of the ceramic powder distribution;
wherein the high dielectric constant composite material comprises the ceramic powder distribution and the polymer. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
- the method comprising;
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33. A method for manufacturing a composite material having a high dielectric constant and comprising a ceramic powder distribution and a polymer binder, the method comprising:
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mixing a first distribution of large ceramic particles, a second distribution of intermediate ceramic particles, a third distribution of other intermediate ceramic particles, and a fourth distribution of small ceramic particles to form the ceramic powder distribution; compacting the ceramic powder distribution such that the compacted distribution has a packing factor of at least 80%; mixing the ceramic powder distribution with a liquid polymer precursor to form a paste; placing the paste into a die; compressing the paste; and
,polymerizing the polymer precursor to form the polymer binder that binds directly to a surface of each of the ceramic particles of the ceramic powder distribution, wherein the polymer precursor is polymerized by heating the die containing the pressed paste for at least thirty minutes and cooling the high dielectric constant composite material, providing a chemical catalyst, exposing the polymer precursor to ultraviolet light, or combinations thereof. - View Dependent Claims (34)
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35. A method for manufacturing a composite material having a high dielectric constant and high dielectric strength, the composite material including a quadmodal distribution of ceramic powder, the method comprising:
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mixing the ceramic powder distribution with a melted polymer in a solvent to form a paste; placing the paste into a die; compressing the paste; and
,cooling the mixture to allow the melted polymer to solidify;
wherein the high dielectric constant composite material comprises the ceramic powder distribution and the polymer. - View Dependent Claims (36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48)
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49. A composite material having a high dielectric constant and high dielectric strength, the composite material comprising:
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a trimodal distribution of high dielectric constant ceramic particles bonded together by a polymeric material, wherein the trimodal distribution comprises 65 to 80% of at least one first ceramic particle having a first diameter in a first range between 40 μ
m and 220 μ
m, 15% to 20% of at least one second ceramic particle having a second diameter in a second range between 500 nm and 5 μ
m, and 5% to 15% of at least one third ceramic particle having a third diameter in a third range between 2 nm and 500 nm; and
,wherein the polymeric material is polymerized in-situ from a polymeric precursor and binds directly to a surface of each of the high dielectric constant ceramic particles.
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50. A composite material having a high dielectric constant and high dielectric strength, the composite material comprising:
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a trimodal distribution of high dielectric constant ceramic particles bonded together by a polymeric material, wherein the trimodal distribution comprises 65 to 80% of at least one first ceramic particle having a first diameter in a first range between 40 μ
m and 220 μ
m, 15% to 20% of at least one second ceramic particle having a second diameter in a second range between 500 nm and 5 μ
m, and 5% to 15% of at least one third ceramic particle having a third diameter in a third range between 2 nm and 500 nm; and
,the polymeric material is a gelling polymer, wherein the polymeric material is mixed with a solvent and the polymeric material absorbs at least a portion of the solvent to increase the volume or the polymeric material.
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51. A composite material having a high dielectric constant and high dielectric strength, the composite material comprising:
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a distribution of high dielectric constant ceramic particles, where the distribution of high dielectric constant ceramic particles is a quadmodal distribution; and a polymeric material, wherein the polymeric material is mixed with the distribution of high dielectric constant ceramic particles and a polymer is formed in situ. - View Dependent Claims (52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80)
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Specification