Density enhancement methods and compositions
AssigneesThe Trustees of Princeton University, Uniformity Labs, Inc.
InventorsAdam Bayne Hopkins, Salvatore Torquato
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Abstract
The present invention relates to granular composite density enhancement, and related methods and compositions. The applications where these properties are valuable include but are not limited to: 1) additive manufacturing (“3D printing”) involving metallic, ceramic, cermet, polymer, plastic, or other dry or solvent-suspended powders or gels, 2) concrete materials, 3) solid propellant materials, 4) cermet materials, 5) granular armors, 6) glass-metal and glass-plastic mixtures, and 7) ceramics comprising (or manufactured using) granular composites.
Claims20
A layer of a granular composite comprising a disordered, flowable powder that does not phase separate during a period of flow and exhibiting a porosity of 25% or less, said layer less than 1000 microns in thickness,
- wherein said granular composite comprises at least two groups of particles such that each group spans a mutually exclusive range of particle volumes, the union of which two or more groups includes all particles in the composite, where the dividing volume between groups is a smallest minimum point in a passing curve or similar size distribution representative of the composite, and where of at least two such groups within the composite, the value of the passing curve or similar size distribution at the smallest minimum point between the two groups is no greater than 75% of the value of the passing curve or similar size distribution at the largest maximum of either of the two groups, the particles associated with the larger of the two groups having an average particle volume that is less than 10,000 times larger than the average particle volume of the particles associated with the smaller of the two groups, wherein
- on average, particles from a larger group contact at least one other particle from the same group, and the force network maintaining mechanical stability of the composite is comprised of non-negligible quantities of particles from both smaller and larger groups.
A layer of a disordered granular composite comprising a flowable suspension that does not phase separate during a period of flow and exhibiting a porosity of 35% or less, said layer less than 1000 microns in thickness,
- wherein said granular composite comprises at least two groups of particles such that each group spans a mutually exclusive range of particle volumes, the union of which two or more groups includes all particles in the composite, where the dividing volume between groups is a smallest minimum point in a passing curve or similar size distribution representative of the composite, and where of at least two such groups within the composite, the value of the passing curve or similar size distribution at the smallest minimum point between the two groups is no greater than 75% of the value of the passing curve or similar size distribution at the largest maximum of either of the two groups, the particles associated with the larger of the two groups having an average particle volume that is less than 10,000 times larger than the average particle volume of the particles associated with the smaller of the two groups, wherein
- on average, particles from a larger group have as nearest neighbors at least one other particle from the same group, and the mixing of a group of smaller particles into a composite occupying a given volume of space and composed only of larger particles increases the volume of space occupied by the mixture.
Dependencies are inferred from the claim text.