Workflow for novel composite materials

Abstract

A method of making a composite material, the method comprising: providing a tile, wherein the tile comprises an inorganic material; and bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material. In some embodiments, the exotherm from the foaming of the foamable exothermic material cures the heat-curable adhering material for a time sufficient to unite a solid foam body to the heat-curable adhering material of the tile and the ductile backing material. The method is particularly advantageous in bonding a tile composed of nano-particles to a ductile backing material, as it helps retain the nanoscale properties of the nano-particles in the tile.

1 . A method of making a composite material, the method comprising:
 providing a tile, wherein the tile comprises an inorganic material; and   bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material.   
     
     
         2 . The method of  claim 1 , wherein the step of bonding comprises:
 wetting an interior surface of the tile with the heat-curable adhering material;   wetting an interior surface of the ductile backing material with the heat-curable adhering material;   forming an interior volume between the tile and the ductile backing material, wherein the interior surface of the tile and the interior surface of the ductile backing material are facing one another, and wherein the interior surface of the tile and the interior surface of the ductile backing material each form a boundary of the interior volume;   inserting the catalyzed foamable exothermic material into the interior volume after wetting the interior surfaces of the tile and the ductile backing material with the heat-curable adhering material, wherein an amount of catalyzed foamable exothermic material is used that is sufficient to fill the entire interior volume when foamed and form a solid foam body between the tile and the ductile backing material; and   allowing the exotherm from the foaming to activate and cure the heat-curable adhering material for a time sufficient to unite the solid foam body to the heat-curable adhering material of the tile and the ductile backing material.   
     
     
         3 . The method of  claim 2 , wherein the step of forming the interior volume comprises sealing the interior volume to a degree sufficient to allow the catalyzed foamable exothermic material to expand and build up interior pressure within the interior volume, thereby creating physical pressurized contact between the catalyzed foamable exothermic material and the heat-curable adhering material of each of the tile and the ductile backing material. 
     
     
         4 . The method of  claim 1 , wherein the adhering material is resin. 
     
     
         5 . The method of  claim 1 , wherein the heat generated during the bonding step does not exceed ¼ of the melting point temperature of the tile. 
     
     
         6 . The method of  claim 1 , wherein the tile comprises sintered nano-powder. 
     
     
         7 . The method of  claim 6 , wherein the tile comprises spark plasma sintered nano-powder. 
     
     
         8 . The method of  claim 6 , wherein the sintered nano-powder comprises ceramic nanopowder. 
     
     
         9 . The method of  claim 8 , wherein the ceramic nano-powder comprises boron carbide. 
     
     
         10 . The method of  claim 6 , wherein the sintered nano-powder comprises ceramic nanopowder and metallic nano-powder. 
     
     
         11 . The method of  claim 1 , wherein the tile comprises sintered powder, the powder comprising particles having a ceramic core with a metallic outer layer. 
     
     
         12 . The method of  claim 11 , wherein the metallic outer layer comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum. 
     
     
         13 . The method of  claim 1 , wherein the ductile backing material comprises a plurality of fibers. 
     
     
         14 . The method of  claim 1 , wherein the ductile backing material comprises a plurality of polyethylene fibers. 
     
     
         15 . A method of making a composite material, the method comprising:
 providing a plurality of nano-particles;   forming a tile from the plurality of nano-particles by performing a spark plasma sintering process on the plurality of nano-particles; and   bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material.   
     
     
         16 . The method of  claim 15 , wherein the step of providing the plurality of nano-particles comprises:
 applying a plasma stream to a precursor powder, thereby vaporizing the precursor powder; and   condensing the vaporized powder, thereby forming the plurality of nano-particles.   
     
     
         17 . The method of  claim 15 , wherein the plurality of nano-particles comprises ceramic material. 
     
     
         18 . The method of  claim 17 , wherein the ceramic material is boron carbide. 
     
     
         19 . The method of  claim 15 , wherein the plurality of nano-particles comprises ceramic material and metallic material. 
     
     
         20 . The method of  claim 19 , wherein the metallic material comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum. 
     
     
         21 . The method of  claim 15 , wherein the step of bonding comprises:
 wetting an interior surface of the tile with the heat-curable adhering material;   wetting an interior surface of the ductile backing material with the heat-curable adhering material;   forming an interior volume between the tile and the ductile backing material, wherein the interior surface of the tile and the interior surface of the ductile backing material are facing one another, and wherein the interior surface of the tile and the interior surface of the ductile backing material each form a boundary of the interior volume;   inserting the catalyzed foamable exothermic material into the interior volume after wetting the interior surfaces of the tile and the ductile backing material with the heat-curable adhering material, wherein an amount of catalyzed foamable exothermic material is used that is sufficient to fill the entire interior volume when foamed and form a solid foam body between the tile and the ductile backing material; and   allowing the exotherm from the foaming to activate and cure the heat-curable adhering material for a time sufficient to unite the solid foam body to the heat-curable adhering material of the tile and the ductile backing material.   
     
     
         22 . The method of  claim 21 , wherein the step of forming the interior volume comprises sealing the interior volume to a degree sufficient to allow the catalyzed foamable exothermic material to expand and build up interior pressure within the interior volume, thereby creating physical pressurized contact between the catalyzed foamable exothermic material and the heat-curable adhering material of each of the tile and the ductile backing material. 
     
     
         23 . The method of  claim 15 , wherein the adhering material is resin. 
     
     
         24 . The method of  claim 15 , wherein the heat generated during the bonding step does not exceed ¼ of the melting point temperature of the nano-particles that form the tile. 
     
     
         25 . The method of  claim 15 , wherein the ductile backing material comprises a plurality of fibers. 
     
     
         26 . The method of  claim 15 , wherein the ductile backing material comprises a plurality of polyethylene fibers. 
     
     
         27 . A composite material comprising:
 a tile comprising inorganic material; and   a ductile backing material,   wherein the tile and the ductile backing material are bonded together via foam material and cured adhering material.   
     
     
         28 . The composite material of  claim 27 , wherein:
 the tile has an interior surface with cured adhering material disposed thereon; the ductile backing material has an interior surface with cured adhering material disposed thereon; and   the foam material is disposed in between and in contact with the cured adhering material on the interior surface of the tile and the cured adhering material on the interior surface of the ductile backing material.   
     
     
         29 . The composite material of  claim 27 , wherein the tile comprises sintered nano-particles that have retained their nanoscale properties. 
     
     
         30 . The composite material of  claim 29 , wherein the plurality of nano-particles comprises ceramic material. 
     
     
         31 . The composite material of  claim 30 , wherein the ceramic material is boron carbide. 
     
     
         32 . The composite material of  claim 29 , wherein the plurality of nano-particles comprises ceramic material and metallic material. 
     
     
         33 . The composite material of  claim 32 , wherein the metallic material comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum. 
     
     
         34 . The composite material of  claim 27 , wherein the adhering material is resin. 
     
     
         35 . The composite material of  claim 27 , wherein the ductile backing material comprises a plurality of fibers. 
     
     
         36 . The composite material of  claim 27 , wherein the ductile backing material comprises a plurality of polyethylene fibers.