Composite materials

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.

1 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein the composite material has a flexural strength of about 12,880-59,090 psi.    
   
   
       2 : The composite material of  claim 1 , wherein the composite material has a flexural strength of about 16,310-27,790 psi.  
   
   
       3 : The composite material of  claim 1 , wherein the composite material has a flexural strength of about 12,880-40,250 psi.  
   
   
       4 : The composite material of  claim 1 , wherein the composite material has a flexural strength of about 14,540-59,090 psi.  
   
   
       5 : The composite material of  claim 1 , wherein the microsphere particles range from about 69% by volume to about 85% by volume of the composite material.  
   
   
       6 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein the composite material has a flexural modulus of about 845,000-5,247,000 psi.    
   
   
       7 : The composite material of  claim 6 , wherein the composite material has a flexural strength of about 2,414,000-4,851,000 psi.  
   
   
       8 : The composite material of  claim 6 , wherein the composite material has a flexural strength of about 1,772,000-5,194,000 psi.  
   
   
       9 : The composite material of  claim 6 , wherein the microsphere particles range from about 69% by volume to about 85% by volume of the composite material.  
   
   
       10 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein the composite material has a compressive strength of about 7,779-54,070 psi in a direction generally perpendicular to the fiber layer.    
   
   
       11 : The composite material of  claim 10 , wherein the composite material has a compressive strength of about 19,670-30,140 psi in the direction generally perpendicular to the fiber layer.  
   
   
       12 : The composite material of  claim 10 , wherein the composite material has a compressive strength of about 24,130-44,060 psi in the direction generally perpendicular to the fiber layer.  
   
   
       13 : The composite material of  claim 10 , wherein the microsphere particles range from about 69% by volume to about 85% by volume of the composite material.  
   
   
       14 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein the composite material has a compressive strength of about 5,624-24,910 psi in a direction generally parallel to the fiber layer.    
   
   
       15 : The composite material of  claim 14 , wherein the composite material has a compressive strength of about 6,190-13,860 psi in the direction generally parallel to the fiber layer.  
   
   
       16 : The composite material of  claim 14 , wherein the composite material has a compressive strength of about 11,730-19,350 psi in the direction generally parallel to the fiber layer.  
   
   
       17 : The composite material of  claim 14 , wherein the microsphere particles range from about 69% by volume to about 85% by volume of the composite material.  
   
   
       18 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein the composite material has an IZOD impact strength of about 8-26 ft-lbs/inch of thickness.    
   
   
       19 : The composite material of  claim 18 , wherein the composite material has an IZOD impact strength of about 13.5-26 ft-lbs/inch of thickness.  
   
   
       20 : The composite material of  claim 18 , wherein the composite material has an IZOD impact strength of about 8-14.7 ft-lbs/inch of thickness.  
   
   
       21 : The composite material of  claim 18 , wherein the composite material has an IZOD impact strength of about 9.5-19.2 ft-lbs/inch of thickness.  
   
   
       22 : The composite material of  claim 18 , wherein the microsphere particles range from about 69% by volume to about 85% by volume of the composite material.  
   
   
       23 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein the composite material has a Young's modulus of about 694,000-5,580,000 psi.    
   
   
       24 : The composite material of  claim 23 , wherein the composite material has a Young's modulus of about 694,000-5,463,000 psi.  
   
   
       25 : The composite material of  claim 23 , wherein the composite material has a Young's modulus of about 1,971,000-5,580,000 psi.  
   
   
       26 : The composite material of  claim 23 , wherein the microsphere particles range from about 69% by volume to about 85% by volume of the composite material.  
   
   
       27 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein when an article is made of the composite material to have a thickness of about 5/16 inch, a front side and a back side, and when heat is applied to the front side such that the front side has a temperature of about 758° F. the back side has a temperature closer to an ambient temperature than to 758° F.    
   
   
       28 : The composite material of  claim 27 , wherein the microsphere particles are in an amount of about 69%-85% by volume.  
   
   
       29 : A composite material comprising: 
 a polymeric material;    microsphere particles in the polymeric material, the composite material being substantially free of voids in the polymeric material between the microsphere particles; and    a flanking layer adjacent the polymeric material;    wherein when a container is made of the composite material to have a thickness of about 3 inches, and when liquid nitrogen at a temperature of about −328° F. is placed inside of the container for about 8 hours an outside wall of the container has a temperature closer to an ambient temperature than to −328° F.    
   
   
       30 : The composite material of  claim 29 , wherein the microsphere particles are in an amount of about 69%-85% by volume.  
   
   
       31 : A method of making a composite material comprising: 
 mixing microparticles in an uncured polymeric material, the microparticles being mixed in an amount of about 69%-85% by volume;    positioning a flanking layer adjacent the mixture of microparticles and uncured polymeric material;    wetting out the flanking layer with the uncured polymeric material; and    curing the polymeric material.    
   
   
       32 : The method of making a composite material of  claim 31 , wherein the mixing step comprises mixing the microparticles and the uncured polymeric material such that the mixture is substantially free of voids.  
   
   
       33 : The method of making a composite material of  claim 31 , further comprising substantially removing any entrained gas in the mixture of microparticles and uncured polymeric material.  
   
   
       34 : The method of making a composite material of  claim 31 , further comprising forming the mixture of microparticles and polymeric material in a desired shape prior to complete curing of the polymeric material.  
   
   
       35 : The method of making a composite material of  claim 31 , further comprising: 
 continuously making the composite material on a continuous process production line; and    cutting the composite material at desired lengths into individual composite material articles.    
   
   
       36 : The method of making a composite material of  claim 35 , further comprising cutting the composite material to have a desired width.  
   
   
       37 : A sheet board made by the method of  claim 31 .  
   
   
       38 : A sheet board made by the method of  claim 35.