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Composite materials

a technology of composite materials and materials, applied in the field of composite materials, can solve the problems of high manufacturing cost, high weight, and high cost of materials, and achieve the effects of improving material properties, reducing the weight of composite materials, and increasing some material properties strength

Inactive Publication Date: 2006-11-30
JAMES HARDIE TECH LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention is about a new composite material made of small particles, such as hollow microspheres, and a matrix material. The small particles are evenly distributed throughout the matrix material and form a network structure that provides strength and other properties to the material. The composite material has a high-density packing of small particles, which results in a lightweight material with improved strength and other properties. The small particles can be made of glass or other materials, and the matrix material can be a resin or other binder material. The technology of the invention can be used to make various products and processes, including encapsulation of materials with matrix materials inside containers.

Problems solved by technology

Examples of problems with existing composite materials and products made from the materials can include high weight, high cost of the materials, high manufacturing costs, and long manufacturing times. Additional examples of problems have included insufficient heat transfer resistance, poor acoustic properties, poor chemical resistance, poor moisture or water resistance, and inferior electrical properties.
Furthermore, existing composite materials insufficiently combine various desired material properties together into a single material.

Method used

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Embodiment Construction

[0026] Although the present invention can be made in many different forms, the presently preferred embodiments are described in this disclosure and shown in the accompanying drawings. This disclosure exemplifies the principles of the present invention and does not limit the broad aspects of the invention only to the illustrated embodiments.

[0027] Generally, the composite materials of the present invention include a matrix material and a plurality of small particles. The matrix material contains a high density of the small particles. Because of the high density of small particles in the matrix material, the small particles are positioned very close to each other. Adjacent small particles may even be in contact with each other. Typically, the composite material includes a greater volume amount of small particles than the volume amount of matrix material. For example, one new composite material has about twice as much small particles as matrix material by volume.

[0028] A preferred em...

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Abstract

New composite materials having a high density of small particles, such as hollow microspheres, in a matrix material are disclosed. The microspheres are densely packed in the matrix material such that adjacent microspheres are positioned in contact with each other or very close together. Fiber flanking may be provided on the opposite sides of a layer of a core of composite material having the small particles and matrix material. Also disclosed are methods of making and using the composite materials.

Description

FIELD OF THE INVENTION [0001] The present invention generally relates to composite materials. More specifically, the present invention relates to composite materials having a high density of small particles, such as hollow microspheres, in a matrix material. The present invention also relates to methods of making and using the composite materials, and products made from the composite materials. BACKGROUND OF THE INVENTION [0002] Composite materials have been used for a variety of applications. Hollow microspheres have also been used as additives to materials. Microspheres have been used as filler materials and additives to paints, plastics, sheet molding compound (SMC), composites, injection molding, adhesives, syntactic foams, and for other applications. However, needs exist for improved composite materials. Furthermore, there are ongoing needs for new materials that have new and enhanced material properties. [0003] Examples of problems with existing composite materials and product...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D03D25/00C08L101/00B29C70/60B29C70/66C08K7/22
CPCB29C70/60B29C70/66Y10T428/2996Y10T428/25Y10T428/2998Y10T428/2982Y10T428/268Y10T428/249922Y10T428/249924Y10T428/249928Y10T428/249971Y10T428/249991Y10T442/30
Inventor KIMBERLY, LAWRENCE
Owner JAMES HARDIE TECH LTD
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