US2014120355A1PendingUtilityA1

Impact resistant material

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Assignee: SDCMATERAILS INCPriority: Dec 15, 2009Filed: Sep 25, 2013Published: May 1, 2014
Est. expiryDec 15, 2029(~3.4 yrs left)· nominal 20-yr term from priority
Inventors:Maximilian A. Biberger
B01J 23/42B32B 2037/1253B28B 11/243B32B 2571/02B01J 37/349B82Y 30/00B32B 2264/107F41H 5/0414B32B 7/12B82Y 40/00C23C 4/134B32B 27/14B32B 5/16B01J 23/8926B32B 37/14B28B 23/0087B32B 37/12B01J 37/00
52
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Claims

Abstract

A method of making a tile, the method comprising: providing a plurality of nano-particles, wherein the plurality of nano-particles comprises a plurality of ceramic nano-particles; and performing a spark plasma sintering (SPS) process on the plurality of nano-particles, thereby forming a tile comprising the plurality of nano-particles, wherein the nano-structure of the nano-particles is present in the formed tile. In some embodiments, the tile is bonded to a ductile backing material.

Claims

exact text as granted — not AI-modified
1 . A method of making a tile, the method comprising:
 providing a plurality of nano-particles, wherein the plurality of nano-particles comprises a plurality of ceramic nano-particles; and   performing a spark plasma sintering (SPS) process on the plurality of nano-particles, thereby forming a tile comprising the plurality of nano-particles, wherein the nano-structure of the nano-particles is present in the formed tile.   
     
     
         2 . The method of  claim 1 , wherein the plurality of ceramic nano-particles comprises boron carbide nano-particles. 
     
     
         3 . The method of  claim 1 , wherein the plurality of nano-particles comprises a plurality of metallic nano-particles. 
     
     
         4 . The method of  claim 3 , wherein the plurality of metallic nano-particles comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum nano-particles. 
     
     
         5 . The method of  claim 1 , 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.   
     
     
         6 . A method of making a composite material, the method comprising:
 providing a plurality of nano-particles, wherein the plurality of nano-particles comprises a plurality of ceramic nano-particles; and   performing a spark plasma sintering (SPS) process on the plurality of nano-particles, thereby forming a tile comprising the plurality of nano-particles, wherein the nano-structure of the nano-particles is present in the formed tile; and   bonding the tile to a ductile backing material.   
     
     
         7 . The method of  claim 6 , wherein the plurality of ceramic nano-particles comprises boron carbide nano-particles. 
     
     
         8 . The method of  claim 6 , wherein the plurality of nano-particles comprises a plurality of metallic nano-particles. 
     
     
         9 . The method of  claim 8 , wherein the plurality of metallic nano-particles comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum nano-particles. 
     
     
         10 . The method of  claim 8 , 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.   
     
     
         11 . The method of  claim 6 , wherein the ductile backing material comprises a plurality of fibers. 
     
     
         12 . The method of  claim 11 , wherein the ductile backing material comprises a plurality of polyethylene fibers. 
     
     
         13 . The method of  claim 6 , wherein the tile is bonded to the ductile backing material using an autoclave process. 
     
     
         14 . The method of  claim 6 , wherein the tile is bonded to the 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. 
     
     
         15 . The method of  claim 14 , wherein the adhering material is resin. 
     
     
         16 . A tile comprising:
 a sintered plurality of ceramic nano-particles,   wherein the plurality of nano-particles maintain their nano-scale properties in the sintered plurality of nano-particles, and the ceramic nano-particles have an average grain size less than 250 nanometers.   
     
     
         17 . The tile of  claim 16 , wherein the ceramic nano-particles comprise boron carbide. 
     
     
         18 . The tile of  claim 16 , wherein the plurality of nano-particles further comprise a metallic material. 
     
     
         19 . The tile of  claim 18 , wherein the metallic material comprises at least one selected from the group consisting of copper, tantalum, titanium, molybdenum, and aluminum. 
     
     
         20 . A material comprising:
 a tile comprising a spark plasma sintered plurality of ceramic nano-particles, wherein the plurality of nano-particles maintain their nano-scale properties in the spark plasma sintered plurality of nano-particles, and the ceramic nano-particles have an average grain size less than 250 nanometers.   
     
     
         21 . The material of  claim 20 , wherein the ceramic nano-particles comprise boron carbide. 
     
     
         22 . The material of  claim 20 , wherein the plurality of nano-particles further comprise a metallic material. 
     
     
         23 . The material of  claim 22 , wherein the metallic material comprises at least one selected from the group consisting of copper, tantalum, titanium, molybdenum, and aluminum. 
     
     
         24 . The material of  claim 20 , further comprising a ductile backing material bonded to the tile. 
     
     
         25 - 28 . (canceled) 
     
     
         29 . The tile of  claim 16 , wherein the ceramic nano-particles are created by vaporizing a ceramic powder with a plasma gun and condensing the vaporized ceramic powder. 
     
     
         30 . The tile of  claim 29 , wherein the vaporized ceramic powder is condensed by a highly turbulent quench chamber. 
     
     
         31 . The tile of  claim 30 , wherein the highly turbulent quench chamber has a Reynolds Number of at least 1000. 
     
     
         32 . The tile of  claim 16 , wherein the tile is formed by spark plasma sintering the plurality of ceramic nano-particles. 
     
     
         33 . The material of  claim 20 , wherein the ceramic nano-particles are created by vaporizing a ceramic powder with a plasma gun and condensing the vaporized ceramic powder. 
     
     
         34 . The material of  claim 33 , wherein the vaporized ceramic powder is condensed by a highly turbulent quench chamber. 
     
     
         35 . The material of  claim 34 , wherein the highly turbulent quench chamber has a Reynolds Number of at least 1000.

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