US4588443A
Expired / Lapsed
US
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Shaped article and composite material and method for producing same
Assignee: Aalborg Portland AS
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Filing: 1981-05-01
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Granted: 1986-05-13
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Expires: 2001-05-01
Abstract
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.
Inventors
- 👤 Hans H. Bache
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 23:17
CPC Classifications
C; C04; C04B; C04B40/00; B; B28; B28B; B28B23/00; B28B23/0081; C04B18/00; C04B18/04; C04B18/14; C04B18/146; C04B28/00; C04B28/02; C04B28/04; C04B30/00; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/91
Claims Analysis
Total Claims: 71
Claim 1
Independent Claim
559 words
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/cm 2 , preferably less than 100 g/cm 2 , articles having at least one dimension of at least one meter and having a minimum cross section of at least 0.1 m 2 , and articles having a complex shape that does not permit its establishment by powder compaction.
Claim 2
Dependent Claim
559 words
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/cm 2 , preferably less than 100 g/cm 2 , articles having at least one dimension of at least one meter and having a minimum cross section of at least 0.1 m 2 , and articles having a complex shape that does not permit its establishment by powder compaction.
Claim 3
Dependent Claim
52 words
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.
Claim 4
Dependent Claim
31 words
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.
Claim 5
Dependent Claim
48 words
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.
Claim 6
Dependent Claim
27 words
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.
Claim 7
Dependent Claim
46 words
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.
Claim 8
Dependent Claim
61 words
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/cm 2 applied to a powder mass consisting of the particles, which particles have retained their geometric identity during the shaping process.
Claim 9
Dependent Claim
17 words
A shaped article as claimed in claim 5 in which the additional bodies D are densely packed.
Claim 10
Dependent Claim
35 words
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.
Claim 11
Dependent Claim
34 words
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.
Claim 12
Dependent Claim
26 words
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.
Claim 13
Dependent Claim
23 words
A shaped article as claimed in claim 9 in which the particles B comprise at least 50% by weight of Portland cement particles.
Claim 14
Dependent Claim
24 words
A shaped article as claimed in claim 12 in which the particles B comprise particles selected from fine sand, fly ash and fine chalk.
Claim 15
Dependent Claim
29 words
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 cm 2 /g.
Claim 16
Dependent Claim
32 words
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.
Claim 17
Dependent Claim
172 words
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.
Claim 18
Dependent Claim
42 words
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.
Claim 19
Dependent Claim
18 words
A shaped article as claimed in claim 17 in which the particles C consist of refractory grade bauxite.
Claim 20
Dependent Claim
34 words
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.
Claim 21
Dependent Claim
17 words
A shaped article as claimed in claim 1 which contains sand and stone as additional bodies D.
Claim 22
Dependent Claim
15 words
A shaped article as claimed in claim 1 which contains fibers as additional bodies D.
Claim 23
Dependent Claim
35 words
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.
Claim 24
Dependent Claim
32 words
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.
Claim 25
Dependent Claim
17 words
A shaped article as claimed in claim 1 which additionally contains reinforcing steel as bars or rods.
Claim 26
Dependent Claim
21 words
A shaped article as claimed in either of claims 23 or 24 in which the bars, rods, or fibers are pre-stressed.
Claim 27
Dependent Claim
29 words
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.
Claim 28
Dependent Claim
78 words
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.
Claim 29
Dependent Claim
15 words
An article as claimed in claim 27 in which the matrix thereof is fiber reinforced.
Claim 30
Dependent Claim
364 words
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/cm 2 , 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.
Claim 31
Dependent Claim
364 words
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/cm 2 , 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.
Claim 32
Dependent Claim
365 words
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/cm 2 , 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.
Claim 33
Dependent Claim
365 words
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/cm 2 , 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.
Claim 34
Dependent Claim
67 words
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/cm 2 .
Claim 35
Dependent Claim
38 words
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.
Claim 36
Dependent Claim
53 words
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 cm 2 /g, the particles B comprise at least 50% by weight of Portland cement, and the dispersing agent is a concrete superplasticiser.
Claim 37
Dependent Claim
68 words
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.
Claim 38
Dependent Claim
28 words
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.
Claim 39
Dependent Claim
45 words
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.
Claim 40
Dependent Claim
23 words
A composite material as claimed in claim 36 in which the alkali or alkaline earth metal salt is a sodium or calcium salt.
Claim 41
Dependent Claim
37 words
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.
Claim 42
Dependent Claim
40 words
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.
Claim 43
Dependent Claim
169 words
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.
Claim 44
Dependent Claim
42 words
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.
Claim 45
Dependent Claim
18 words
A composite material as claimed in claim 41 in which the particles C consist of refractory grade bauxite.
Claim 46
Dependent Claim
16 words
Shaped articles produced from the composite material claimed in either of the claims 29 or 30.
Claim 47
Dependent Claim
484 words
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/cm 2 , 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.
Claim 48
Dependent Claim
484 words
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/cm 2 , 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.
Claim 49
Dependent Claim
143 words
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 m 2 , and/or has a complex shape which does not permit its establishment by powder compaction.
Claim 50
Dependent Claim
143 words
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 m 2 , and/or has a complex shape which does not permit its establishment by powder compaction.
Claim 51
Dependent Claim
191 words
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.
Claim 52
Dependent Claim
191 words
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.
Claim 53
Dependent Claim
51 words
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.
Claim 54
Dependent Claim
351 words
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.
Claim 55
Dependent Claim
45 words
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.
Claim 56
Dependent Claim
52 words
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.
Claim 57
Dependent Claim
351 words
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.
Claim 58
Dependent Claim
351 words
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.
Claim 59
Dependent Claim
56 words
A shaped article comprising a matrix comprising fibers having a transverse dimension of less than 100 μm and bodies or particles of a size of from about 50 Å to about 0.5 μm homogeneously arranged and substantially densely packed in the voids between the fibers, the fiber volume percentage of the matrix being at least 30%.
Claim 60
Dependent Claim
56 words
A shaped article comprising a matrix comprising fibers having a transverse dimension of less than 100 μm and bodies or particles of a size of from about 50 Å to about 0.5 μm homogeneously arranged and substantially densely packed in the voids between the fibers, the fiber volume percentage of the matrix being at least 30%.
Claim 61
Dependent Claim
15 words
A shaped article according to claim 52 wherein the fiber volume is at least 40%.
Claim 62
Dependent Claim
19 words
A shaped article according to claim 52 or 53 wherein the inter-particle substance is a metal or plastics material.
Claim 63
Dependent Claim
335 words
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.
Claim 64
Dependent Claim
335 words
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.
Claim 65
Dependent Claim
333 words
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.
Claim 66
Dependent Claim
333 words
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.
Claim 67
Dependent Claim
58 words
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.
Claim 68
Dependent Claim
24 words
A shaped article according to claim 14 in which the silica dust particles have a specific surface area of about 250,000 cm 2 /g.
Claim 69
Dependent Claim
26 words
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.
Claim 70
Dependent Claim
26 words
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.
Claim 71
Dependent Claim
24 words
A shaped article according to claim 33 in which the silica dust particles have a specific surface area of about 250,000 cm 2 /g.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-05-12 | 1989-11-11 | 1990-05-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-05-12 | 1993-11-11 | 1994-05-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-05-12 | 1997-11-11 | 1998-05-13 | $7700.00 | Window Closed / Lapsed |