Engineered Reactive Matrix Composite Coating Control

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Solution Overview

Problem

Current sintering technologies for metals and ceramics lack effective control over reactivity and mechanical properties, particularly in response to external stimuli, due to limitations in coating uniformity and interaction with core particles.

Innovation Solution

The development of engineered reactive matrix composites with a core material and a reactive binder matrix, where the binder is distributed homogeneously or in controlled arrangements, and a thin, continuous coating is applied to the surface of particles to enhance reactivity and mechanical properties, allowing for controlled reaction kinetics in response to external stimuli.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional sintering technologies are used for metals and ceramics, then the manufacturing process is simple, but the control over reactivity and mechanical properties is poor

Engineering Contradiction:

Improvecontrol over reactivity and mechanical propertiesVSAvoidcoating application process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by coating the particle surfaces with reactive materials before the sintering process. This pre-coating step ensures that the particles have controlled reactivity and mechanical properties from the outset, allowing for better control over the final composite's behavior during sintering and in response to external stimuli.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by varying the coating thickness, composition, and application method to precisely control the reactivity and mechanical properties of the particles. By adjusting these parameters, the invention achieves tailored composite materials with specific performance characteristics while managing the complexity of the coating process.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If coatings are applied to particle surfaces to enhance reactivity, then the mechanical properties improve, but the coating uniformity is difficult to achieve

Engineering Contradiction:

Improvereactivity controlVSAvoidcoating uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical coating methods with chemical vapor deposition or solution-based coating techniques. These alternative methods allow for more uniform coating distribution on particle surfaces by utilizing chemical reactions or solution penetration rather than mechanical application, thereby improving coating uniformity while maintaining enhanced reactivity and mechanical properties.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If reactive materials are blended with core particles, then the reaction kinetics improve, but the distribution homogeneity is poor

Engineering Contradiction:

Improvereaction kineticsVSAvoiddistribution homogeneity

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent applies segmentation by dividing the reactive material into thin coating layers on individual particle surfaces rather than blending bulk reactive materials with core particles. This segmentation ensures that each particle has a controlled amount of reactive material on its surface, leading to homogeneous distribution throughout the composite while maintaining fast reaction kinetics when the particles are activated.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables more predictable, cost-effective fabrication of reactive composite parts with improved homogeneity and repeatable performance, overcoming previous limitations by ensuring simplified handling and production of sintered compacts with enhanced reactivity and mechanical properties.

Implementation Method 1

the combination can be made to react in a controlled fashion in response to the imposition of an external stimulus, such as shear (e.g., impact), thermal (high temperature ignition), or catalysis or activation

Methodology Applied

Scientific EffectThermal ignition: Combustion

Implementation Method 2

Sintered products of inorganic non-metallic or metallic powders have been used in structural parts

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11530170B2Material and method of manufacture for engineered reactive matrix composites

Publication Date: 2022.12.20 POWDERMET INC

AI summary

A high strength engineered reactive matrix composite that includes a core material and a reactive binder matrix combined in high volumes and with controlled spacing and distribution to produce both high strength and controlled reactivity. The engineered reactive matrix composite includes a repeating metal, ceramic, or composite particle core material and a reactive binder/matrix, and wherein the reactive/matrix binder is distributed relatively homogeneously around the core particles, and wherein the reactivity of the reactive binder/matrix is engineered by controlling the relative chemistry and interfacial surface area of the reactive components. These reactive materials are useful for oil and gas completions and well stimulation processes, enhanced oil and gas recovery operations, as well as in defensive and mining applications requiring high energy density and good mechanical properties.