Self-Repairing, Reinforced Matrix Materials

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.

1 . A shaped article comprising a cured composite concrete matrix material having release vessels and a modifying agent therein, wherein the modifying agent is capable of modifying the composite matrix material in response to a stimulus.  
     
     
         2 . The article of  claim 1 , wherein the cured concrete matrix material comprises cement.  
     
     
         3 . The article of  claim 1 , wherein the modifying agent is a water binding hydroscopic chemical agent.  
     
     
         4 . The article of  claim 1  wherein the modifying chemical is selected from the group consisting of polyolefin, polyester, polyamide, polyaramid, polyimide, carbon, graphite, cellulose, nitrocellulose, polysiloxane, epoxy, hydrocarbon, polytetrafluoroethylene, polyurethane, aramid, polypropylene, elastomer, one- and two-part adhesives, one- and two-part epoxy adhesives, cyanoacrylate adhesives, Elmer's glue, amines, polysiloxanes, sealant, siloxane, silica additives, calcium nitrate, polyprolylene glycol, epoxy precursers, polymerizable monomers, methyl methacrylates, styrene, acids, bases, solvents, cement, fly ash, bottom ash, phosphoric acid, ceramic, silicon oxide, titanium oxide, silicon nitride, metals, aluminum, steel, metal alloys, asphalt, thermoplastic polymers, thermosetting polymers, thermoplastic elastomers, crosslinkable polymers, curable polymer resin systems, hydroxyapatite, polyolefins, polyesters, polycarbonates, polyacrylates, polyarylates, polyamides, polyurethanes, foaming polyurethanes, crosslinkable polymers, curable resin systems, phenolformaldehyde resins, rubbery polymers, butadiene, rubber, neoprene, SEBS, NBR, and EPDM rubbers, viscoelastic materials, latexes, sinterable ceramics, silicas, titanium, carbides, oxides, alumina, iron, lead, copper, steel, bronze, phosphor bronze, brass, bone and calcium salts.  
     
     
         5 . The article of  claim 1  wherein the release vessels comprise fiberglass, cement, asphalt, hydroxyapatite, glass, ceramic, metal, polyolefin, polyester, polycarbonate, polyacrylate, polyarylate, polyamide, polyimide, polyaramide, polyurethane, carbon, graphite, cellulose, nitrocellulose, hydrocarbon, shape memory alloys, or magnetostrictive piezoelectric material.  
     
     
         6 . The article of  claim 1  wherein the release vessels have a coating therein.  
     
     
         7 . The article of  claim 6  wherein the coatings comprise wax, polyol, polymers, ceramics, shellac, epoxy resins, polyester resins, polyurethane resins, acrylic resins or nylon.  
     
     
         8 . The article of  claim 1 , wherein the modifying agent is a silicate.  
     
     
         9 . The article of  claim 1 , further comprising a calcium salt.  
     
     
         10 . The article of  claim 1  further comprising at least one hollow release vessel having the modifying agent therein.  
     
     
         11 . The article of  claim 10 , wherein the hollow release vessel is a hollow particle.  
     
     
         12 . The article of  claim 1  in which the article is used for roads, highways, bridges, buildings, infrastructure, or ports.  
     
     
         13 . The article of  claim 1  in which the matrix also contains metal.  
     
     
         14 . The article of  claim 13 , wherein the article resists cracking, corrosion, and oxidation.  
     
     
         15 . The article of  claim 13 , wherein the stimulus is at least one of heating, cooling, loading, impacting, cracking, water infusion, chloride infusion, alkalinity changes, acidity changes, acoustic excitation, low frequency wave excitations, hydrostatic pressure, rolling pressure, light sensitivity, laser excitation, electrical currents, voltages, electrorheological excitation, radiation, heat caused by fire or impact caused by earthquake.  
     
     
         16 . A shaped article comprising a cured composite matrix material having a modifying agent therein, wherein the modifying agent is capable of beneficially modifying the composite matrix material in response to a stimulus, wherein the cured matrix material comprises ceramic material.  
     
     
         17 . The article of  claim 16 , wherein the release vessel is a hollow particle.  
     
     
         18 . The article of  claim 16  wherein the release vessels comprise fiberglass, cement, asphalt, hydroxyapatite, glass, ceramic, metal, polyolefin, polyester, polycarbonate, polyacrylate, polyarylate, polyamide, polyimide, polyaramide, polyurethane, carbon, graphite, cellulose, nitrocellulose, hydrocarbon, shape memory alloys, or magnetostrictive piezoelectric material.  
     
     
         19 . The article of  claim 16  wherein the modifying chemical is selected from the group consisting of polyolefin, polyester, polyamide, polyaramid, polyimide, carbon, graphite, cellulose, nitrocellulose, polysiloxane, epoxy, hydrocarbon, polytetrafluoroethylene, polyurethane, aramid, polypropylene, elastomer, one- and two-part adhesives, one- and two-part epoxy adhesives, cyanoacrylate adhesives, Elmer's glue, amines, polysiloxanes, sealant, siloxane, silica additives, calcium nitrate, polyprolylene glycol, epoxy precursers, polymerizable monomers, methyl methacrylates, styrene, acids, bases, solvents, cement, fly ash, bottom ash, phosphoric acid, ceramic, silicon oxide, titanium oxide, silicon nitride, metals, aluminum, steel, metal alloys, asphalt, thermoplastic polymers, thermosetting polymers, thermoplastic elastomers, crosslinkable polymers, curable polymer resin systems, hydroxyapatite, polyolefins, polyesters, polycarbonates, polyacrylates, polyarylates, polyamides, polyurethanes, foaming polyurethanes, crosslinkable polymers, curable resin systems, phenolformaldehyde resins, rubbery polymers, butadiene, rubber, neoprene, SEBS, NBR, and EPDM rubbers, viscoelastic materials, latexes, sinterable ceramics, silicas, titanium, carbides, oxides, alumina, iron, lead, copper, steel, bronze, phosphor bronze, brass, bone and calcium salts.  
     
     
         20 . A shaped article comprising a cured composite matrix material having a modifying agent therein, wherein the modifying agent is capable of beneficially modifying the composite matrix material in response to a stimulus, wherein the cured matrix material comprises piezoelectric material.  
     
     
         21 . The article of  claim 20  in which the piezoelectric material is a ceramic.  
     
     
         22 . The article of  claim 20  in which the piezoelectric material is a polymer.  
     
     
         23 . A shaped article comprising a cured composite matrix material having a modifying agent therein, wherein the modifying agent is capable of beneficially modifying the composite matrix material in response to a stimulus, wherein the cured matrix material comprises shape memory material.  
     
     
         24 . The article of  claim 23  in which the shape memory material is a metal.  
     
     
         25 . The article of  claim 23  in which the shape memory material is polymer.